MSCL Handling Instal Manual 2007

S I N T A K O T E
S T E E L
P I P E L I N E S
SINTAKOTE
Steel pipeline systems
Handling & Installation Reference Manual
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Contents
Section
1. 2. 3. 4.
Copyright Tyco Water Pty Ltd This manual is a publication of Tyco Water Pty Ltd, and must not be copied or reproduced in whole or part without the Companys prior written consent. This manual is and shall remain the Companys property and shall be returned to the Company on its request. The Company reserves the right to make changes to any matter at any time without notice. Fifth edition published 2007
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Transportation ........................................................................................12 Site Preparation ......................................................................................13 Unloading and Handling ........................................................................14 Stacking and Storage ............................................................................16 Stringing..................................................................................................19 Trenching ................................................................................................21 Bedding ..................................................................................................23 Laying and Jointing ................................................................................24 Backfilling................................................................................................40
5. 6. 7. 8. 9.
Disclaimer
This manual has been prepared by Tyco Water to assist qualified Engineers and Contractors in the use of the Companys product, and is not intended to be an exhaustive statement on pipeline design, installation or technical matters. Any conclusions, formulae and the like contained in the manual represent best estimates only and may be based on assumptions which, while reasonable, may not necessarily be correct for every installation. Successful installation depends on numerous factors outside the Companys control, including site preparation and installation workmanship. Users of this manual must check technical developments from research and field experience, and rely on their knowledge, skill and judgement, particularly with reference to the quality and suitability of the products and conditions surrounding each specific installation. When pipeline construction is being carried out for any water authority, as Principal, that water authoritys standards, specifications or drawings, if at variance to any recommendation made in this manual, override the recommendations made in the manual. The Company disclaims all liability to any person who relies on the whole or any part of this manual and excludes all liability imposed by any statute or by the general law in respect of this manual whether statements and representations in this manual are made negligently or otherwise except to the extent it is prevented by law from so doing. The manual is not an offer to trade and shall not form any part of the trading terms in any transaction. Tyco Water trading terms contain specific provisions which limit the liability of Tyco Water to the cost of replacing or repairing any defective product.
10. Fittings ....................................................................................................43 11. Anchorage of Pipelines ..........................................................................44 12. Hydrostatic Field Test ............................................................................46 13. Commissioning Water Pipelines ............................................................48
Appendices
APPENDIX A Field Repair and Joint Reinstatement of SINTAKOTE ..................................49 APPENDIX B Field Repair and Joint Reinstatement of Cement Mortar Lining ....................58 APPENDIX C Field Application of Electrical Cables to CP Lugs ..........................................61 APPENDIX D General Data ..................................................................................................63
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Contents
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Contents
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List of Figures & Tables

Figure 1.1- Securing pipes for transport..........................................................................12 Figure 3.1Table 4.1 Twin slings or spreader bar ..........................................................................15 Minimum pipe support area ..........................................................................16 Figure 4.1 - Pipe support ................................................................................................16 Figure 4.2 - Pipe bearing area ........................................................................................17 Figure 4.3 - Stacking pipes using timber bolsters.............................................................17 Figure 5.1 - Single stringing of pipes................................................................................20 Figure 5.2 - Multiple stringing of pipes ............................................................................20 Figure 6.1 Figure 7.1 Trench excavation machinery ........................................................................22 Bedding layer minimum depth ........................................................................23
List of Figures & Tables
(continued) Figure 10.1 - Common fittings - welded pipelines ..............................................................43

Figure 10.2 - Common fittings - SINTAJOINT pipelines ......................................................43 Figure 11.1 - Anchor blocks for horizontal thrust restraint....................................................44 Figure 11.2 - Anchor blocks for vertical thrust restraint ......................................................45 Figure 11.3 - Pier support for above ground SINTAJOINT pipelines ....................................45 Figure 12.1 - Static head allowance for hydrostatic test with alternative pressure gauge locations..............................................................................46 Figure A.1 - Flow chart for determining appropriate SINTAKOTE repair method..................49 Figure A.2 - Joint region for Drader welding repair ..........................................................53 Figure A.3 - Drader gun assembly ..................................................................................54 Figure A.4 - Drader gun tip selection................................................................................55 Figure A.5 - Build up of material on cut end ....................................................................56 Figure A.6 - Care required when trimming ........................................................................56 Figure B.1 - Typical cement mortar lining crack greater than 2mm.....................................60 Figure B.2 - Enlarge crack to 4 - 6mm ............................................................................60 Figure B.3 - Completed repair ........................................................................................60 Table D.1 Table D.2 Table D.3 Table D.4 SINTAKOTE Thicknesses..............................................................................63 Cement Mortar Lining (CML) Thickness ........................................................63 SINTAKOTE Steel Pipe Bores and Weights ..................................................63 Manufacturing test pressure and rated pressure of MSCL pipes ....................67
Figure 7.2 - Spreading bedding ......................................................................................23 Figure 8.1 - Jointing systems ..........................................................................................24 Figure 8.2 - Pulling SINTAJOINT pipes home to joint ......................................................25 Figure 8.3 - Fitting rubber rings into sockets ....................................................................27 Figure 8.4 - Alignment of pipes during jointing..................................................................28 Table 8.1 Permissible misalignment and offsets during entry ........................................29 Figure 8.5 - Temporary construction and permanent SINTAJOINT deflection ....................30 Figure 8.6 - Axial offset measurement created by joint deflection ......................................31 Figure 8.7 - External inspection of assembled SINTAJOINT ..............................................32 Figure 8.8 - Welded ball and socket or slip-in joint field assembly ....................................33 Figure 8.9 - Raised face type flanges ..............................................................................34 Figure 8.10 - Matched o-ring type flanges ........................................................................34 Figure 8.11 - Star pattern tightening sequence ..................................................................34 Table 8.2 Table 8.3 Table 8.4 Table 8.5 Recommended gasket composition for transport of general domestic liquids including brine and sewage ..........................................................................35 Recommended Bolt Torques for Steel Flange Class 14 (AS4087 Fig B7) ......36 Recommended Bolt Torques for Steel Flange Class 21 (AS4087 Fig B8) ......37
Recommended Bolt Torques for Raised Face Steel Flange Class 35 (AS4087 Fig B9) ..........................................................................................38 Figure 9.1 - Zones of backfill and compaction..................................................................40 Figure 9.2 - Ring deflection limits ....................................................................................42 continued...
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SINTAKOTE Training Program

The SINTAKOTE Quality Pipeline Installation Program was introduced by Tyco in 1989 and, to date,
(R)
over 4,000 Water Industry personnel have participated. This program assesses individuals through compentency-based training and assessment, the application of an adherence to Quality, Safety, Environmental and Risk Systems. In line with Tyco Water's commitment to continuous improvement, the program is accredited by the Vocational Education and Training Board of NSW (VETAB NSW). The program has been running for many years and is recognised as an Industry Leader. The Accreditation can be seen as a QA measure to ensure training for steel pipeline systems meets the most appropriate specifications. The basis for the Program and the Accreditation is the Tyco Water Handling and Installation Manual and the Pipeline Installation Quality System, commonly known as the PIQS Manual. Tyco Water Training & Auditing - Registered Training Organisation Services On-Site Auditing Technical & Systems Support Pre Qualification of Installers On Site and Off Slite Training Benefits To Customer Confidence in installers Quality Installation Reduce Unscheduled Maintenance Traceability Confidence in Asset Performance Asset Longevity Lower risk rating To Installer Certification of workers Ability to tender for more work Lower risks Increase efficiencies Confidence in work Less Re-work Lower Injury Rates
Risk & Safety Tyco Water is a strong advocate of Safety in the Workplace and believes that safety is paramount in all that we do. All contracts and installers should commit to providing a work enviornment where everyone in the workplaced is safe at all times and recognise people as their greatest asset. The safe handling and installation of the SINTAKOTE Pipeline System in all applications relies on all personnel having a high level of safety awareness, reducing risk and improving site preparations and planning. Steps to Safety Responsibilities for Workplace safety Be aware who has specific responsibilities Plan to Work Safely Identify tasks and procedures, which control the risks arising from work activities Involve Employees Display information in your workplace concerning health & safety. All employees should talk about ways to contribute to decisions that affect their safety in the workplace. Develop Procedures Identify hazards in your workplace and assess any risks associated with them. (Mitigate these hazards through developing processes to eliminate or control). Inform and Train Employees Inform employees about hazards in their job Monitor and Review Adjust, review and address any workplace or legislative changes. Processes change, staff change and so may the risks. Plant & Equipment Regularley assess, inspect equipment and maintain records. Ensure appropriate Licenses are held for Plant in use The above steps may be undertaken throughout and continued through the On-Site Inductions, Toolbox Meetings, or Site Assessments. Remember you may have Principal Contractor's obligations whereby you may be responsible for: Injury or accidents to members of the public; employees and other on site contractors, at or near a construction site or workplace.
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Environmental Tyco Water embraces environmental protection and ensures its operations comply with relevant environmental legislation. Accordingly, Tyco Water as well as SINTAKOTE pipeline Installers and Contractors have a responsibility to ensure your work activites do not harm the environment.
You are expected to take all reasonable and practical measures to ensure that:n Waste (spoil, concrete, off-cuts, etc) is minimised and disposed of in the correct manner
n Water quality is not affected and contaminated run-off from site is prevented. n Soil erosion and sediment control is reduced n Soil does not become contaminated (either from imported fill or excavation material. n Care is taken when handling and using hazardous substances n The effect on air quality is minimised, through dust and pollution control measures. n Mininimise disturbance to existing flora and fauna. Restore vegitation on completion of the works. , n Disruptions to surrounding services are to be minimised. n Noise emissions are kept within required limits. . n Traffic and the movement of plant & equipment around the site does not impact the environment n Vibration to adjacent buildings and area should be minimised n Impact on heritage and archaeological sites should be minimised. n Report any environment incidents to environmental authorities or units. Further details can be gained from state government, Environment Agencies, Local Councils and also from industry bodies.. . Risk Management. . Legislation in all states and territories requires an employer to identify all hazards in their workplace and to assess the likelihood and severity of harm that may arise from such hazards. The Australian Risk Management Standard AS 4360 contains greater details regarding the Risk Management Process. . Risk Management mean Looking at the Work and ProcessesYou Are About to Undertake that could cause injury (entrapment), Making a Judgement on the Consequence and Likelihood of what could happen as a result (death or injury to persons in an excavation), and doing something about it .
This manual has been prepared by Tyco Water Pty Ltd. It is intended to provide guidance on the field practices of handling and installation of SINTAKOTE steel pipelines. Adherence to these guidelines should ensure that the SINTAKOTE steel pipeline system will have the capacity to perform in excess of one hundred years. There may be aspects of handling and installation not covered in this manual which
may become subject to revision. For this reason and in the interests of continuous improvement, feedback on the manual is encouraged. Inquiries or contributions should be directed to the Manager Marketing, Steel Pipeline Systems, Tyco Water, PO Box 141, Fairfield NSW 1860 Australia. Or email info@tycowater.com
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1. Transportation
Secure the load
All pipes must be secured by straps or other suitable means to prevent movement during transit and be in compliance with all local and state regulations regarding load restraint. The width of bolster must provide sufficient area of support to protect the pipe coating. A minimum bolster width of 150mm is required. Double scalloped bolsters should be used to separate layers of stacked pipe and pipes in the same row spaced so that they do not touch. Scallops must be cut to suit the outside diameter of the pipe and have a minimum saddle angle of 90 degrees. The bottom bolsters should be securely anchored to the floor or side of the road truck or rail carriage. The load should be strapped securely at a minimum of two locations, not more than 500 mm from the bolsters and using webbing straps with a minimum lashing capacity of 2000kg. Multiple straps may be necessary at each location. See Figure 1.1.
2. Site Preparation
Good site preparation maximises safety and can save time and money
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Site checks
While preparing sites remember to check for :
Vehicle access
road conditions warning signs traffic control load limitations all weather access
Protect the pipe and coating

Factory installed toms are installed in some pipes sizes and should be maintained in place until after installation. All supports, restraints and packing bearing on pipe surfaces should be covered or wrapped with material suitable to prevent chafing and shock damage during transit. In the case of rail transport, end protection should be provided against shunting shocks. Rubber mats, carpet etc. are suitable for this purpose.
Storage compounds
convenience of location security site dunnage availability protection from weather
Stacking areas
uneven surfaces that may require grading stability in bad weather clear of grass in case of fire overhead power lines other services
The strapping should be securely anchored with approved ratchet type devices and If bolsters are utilised only two per pipe length should be checked for tension at regular should be used. Each should be placed 0.2 intervals not exceeding 300 kilometres of to 0.25 of the length from each pipe end travel. Chains shall not be used to tie down (outside quarter points). See Figure 1.1 pipes or piles. Bolster locations 0.2 to 0.25 of the pipe length from each end This may be varied to suit vehicle load requirements. 500mm 500mm
General
local traffic overhead powerlines location of other services
Figure 1.1 Securing pipes for transport 12 | C H A P T E R 1

PPE is it on
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PPE is it on
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3. Unloading and Handling

Personnel involved in unloading and handling should wear personal protection equipment as required by the Occupational Health and Safety Act. Such as hardhat, safety shoes, safety glasses, high visibility vest and other equipment. Attention to the following items improves efficiency of the operation, maximises safety and minimises risk of damage. Steel pipes are not susceptible to breakage but poor handling can result in damaged coatings and/or linings and damage to the pipe ends. Damage to pipeline components will be prevented by; adequate support and restraint during transportation to site. proper use of handling equipment use of suitable handling equipment correct site storage unloading on even ground correct handling of load When factory fitted cathodic protection (CP) lugs are provided, extra care must be taken to ensure that the lugs are not damaged and that pipes are not bumped together as the lugs may damage coating on adjacent pipes.
Unloading
(See also Section 5: Stringing)
Immediately upon receipt, all items should be visually examined for damage to; the pipe itself, particularly the ends cement mortar lining external coating rubber rings lubricant containers All repair work should be carried out promptly. Refer Appendices A: Field repair and joint reinstatement of SINTAKOTE and B: Field repair and joint reinstatement of cement mortar linings. Check that the correct quantities of materials have been received. Unload the truck evenly to keep it stable. Figure 3.1 Twin slings or spreader bar
Twin sling
Guide ropes
Spreader bar
Guide ropes
Lifting operations
All lifting operations must meet legal and occupation, health and safety requirements applicable to the site. Qualified personnel must be employed for crane operation. When unloading by mobile crane, a licensed dogman must be present. Lifting should be done smoothly without sudden jerking motions. Pipe movement should be controlled by use of guide ropes and care taken not to bump other pipes or equipment. See Figure 3.1. Lifting and placing must be carried out so that the stability of the pipe stack, crane or vehicle is maintained.
When conditions are suitable, forklifts may be used. The contact surfaces of the tynes must be protected with thick rubber with a minimum durometer hardness (Shore D) of 45.
Use twin slings, spreader bar or other approved lifting devices. See Figure 3.1 Slings and lifting devices must comply and be used in accordance with the appropriate safety requirements. The slings shall be of nylon or synthetic material of sufficient width that shall not damage the coated surface of the pipe or pipe fitting.
Choosing equipment
When choosing lifting equipment consider pipe weights (Appendix D: General data; Table D.3) type of stacking outreach site conditions
Before unloading
Choose a central storage site for general use, storage of small components, gaskets, etc. Choose and prepare suitable pipe storage sites along the pipeline route. If possible, select unloading and storage areas which are clear of overhead powerlines. Make sure the truck is on level ground before releasing the straps.
Vacuum Lifting Devices

Vacuum lifting devices are available to lift pipes. These should be used in accordance with the manufacturers specifications.
Accessories
Slings
Pipes should be handled one at a time.
Hooks
Hooks should not be used for lifting pipes or fittings.
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Remember public safety at your site, even when you are not there!
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Remember public safety at your site, even when you are not there!
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4. Stacking and Storage

2 supports 2.5 to 3.0 metres or 0.2 to 0.25 of the pipe length from each end
Stacking heights for long term storage

CP Lugs if provided Pipes 610 mm OD and larger should be stored in single layers only. Pipes less than 610 mm OD may be stacked. To prevent damage to the SINTAKOTE and for safety and handling reasons pipe stacks must not exceed 2m in height. Stacks should never be higher than they are wide. Timber bolsters of minimum cross section dimensions: 150mm wide x 150mm clear depth between scallops, should be used to separate layers. The scallops shall have a minimum saddle angle of 90 degrees. In termite infested areas, timber bolsters may not last unless the area is treated. Otherwise, the bottom bolster should be made from steel. Bottom bolsters must also be placed on firm ground and must be level.
500mm
Sawdust bags
Soil mounds
Figure 4.1 - Pipe support
Figure 4.2 - Pipe bearing area clear of the ground. Beware of protruding rocks and uneven ground. If pipes are provided with factory fitted CP lugs ensure that pipes are stored with lugs at the top. The pipe should be supported at two locations 0.2 to 0.25 of the pipe length from each end. See Figure 4.1. Each support shall provide adequate bearing area. The bearing area on the pipe should not be less than that shown in Table 4.1. See Figure 4.2. It is recommended that pipes be supported on sawdust filled bags or sand mounds. The supports should be positioned to ensure that each pipe is stable. For long term storage, sand mounds should be protected from erosion. The entire pipe must be kept clear of the ground to protect the coating from damage. It is recommended that pipes be separated from each other for ease of inspection and to minimise the potential for damage during handling.
500mm
Storage area
The storage area should have a firm foundation for pipe stacks and vehicle operation have suitable access for road vehicles be free of overhead power lines wherever possible be barricaded if necessary
Pipe support
Coated pipes should at all times be supported
Minimum Support Bearing Area Pipe Length 6m mm2 813 >813 to 1403 >1403 to 1753 > 1753 10,000 10,000 15,000 20,000 9m mm2 10,000 15,000 20,000 30,000 12 13.5m mm2 10,000 20,000 30,000 40,000 Bolster locations 2.5 to 3.0 metres or 0.2 to 0.25 of the pipe length from each end. Figure 4.3- Stacking pipes using timber bolsters.
Table 4.1- Minimum pipe support area
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Remember pipes can easily be rolled and moved. Make sure they are secure!
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5. Stringing
Storage
Small fittings, rubber rings and lubricant should be stored in a secure convenient area. Lubricant must not be stored for lengthy periods in direct sunlight. Rubber rings should be stored in bags, out of the sun and away from petroleum products. They should be stored in a manner that prevents them from being subject to high compressive or tensile strains. Rubber rings should be used within 12 months. If rubber rings are stored for longer periods they should be discarded. such conditions, the wider the cracks will be and the greater the extent of any disbondment (drumminess). Cracks up to 2mm in width (as allowed in AS 1281, Cement Mortar Lining of Steel Pipes and Fittings) are acceptable for pipes conveying potable water as these cracks close and heal on exposure to water. When pipes greater than 800mm in diameter are stored for more than a few weeks in hot, dry conditions, cracks may develop in excess of the 2mm allowable under AS 1281 and the lining may disbond. In such circumstances precautions should be taken such as end capping (to reduce airflow and thus rate of cracking) and adding water to the pipes (to reduce the width of cracks). Guidelines for repair when cracks or disbondment exceeds 2mm are found in Appendix B - Field repair and joint reinstatement of cement mortar lining.
Before pipe delivery

Plan stringing before arrival of the pipe and consider: the construction programme the ground conditions, and the safety of workers and the general public
Always use approved slings and accessories. For large pipes, twin slings should be used, Refer to Section 3: Unloading and handling; Accessories. Guide ropes should be used to control the pipe. See Figure 3.1.
Method of stringing pipes

Keep pipes close to the ground while they are being moved. Pipes should be near enough to the trench for the laying crew, but far enough away so they dont interfere with equipment access, trench digging or excavated spoil. When single stringing, pipes should be in line with the trench with sockets facing the direction of laying such that when laying, a spigot is inserted into an already laid socket. This is the recommended technique for jointing and allows the entry of the spigot into the socket to be more easily seen and controlled. It also minimises the risk of scooping bedding material into the joint and onto mating surfaces. See figure 5.1.
Where to string
Pipe should be located to minimise handling during the laying operation. Pipes should be properly supported. Refer Section 4: Stacking and storage. Large fittings and valves should be put adjacent to where they will be needed. Small fittings, gaskets, nuts and bolts should be kept in a secure storage area until they are needed.
Storage of Cement Mortar Lined Pipes

Cement mortar lining may crack and possibly disbond when stored in hot, dry conditions. The longer the storage period in
What equipment to use

Cranes, forklifts or other appropriate equipment approved by the relevant State Occupational Health & Safety Authority may be used.
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6. Trenching
Before excavation
Locate and mark other underground utility service lines. Check whether the water table needs to be lowered with dewatering equipment. Assess trench stability and shoring requirements.
As a guide, the following trench minimum widths are reasonable:
OD + 400mm for pipe diameters OD + 600mm for pipe diameters OD + 700mm for pipe diameters 0.25 x ODmm for pipe diameters 450mm > 450mm , 900mm > 900mm , 1500mm >1500mm
Figure 5.1- Single stringing of pipes When laying pipe on steep slopes, construction should start at the bottom and proceed up hill. In this way the weight of the pipes is used to advantage when jointing. Pipes should thus be strung with sockets facing uphill. See Figure 5.1.
How wide should the trench be?

The trench width should be as narrow as practicable, consistent with the need to ensure; proper laying and jointing of the pipe, eg. joint stations for welder in welded joint pipelines, application of joint wrapping for welded joint pipelines, where a change in direction is being made at a joint, the trench should be wide enough to allow the joint to be made with the pipes aligned. The pipe should then be deflected after jointing, proper haunch support and compaction of the backfill in accordance with the design specification, use of common size backhoe / excavation bucket widths which are 300, 450, 600, 750, 900, 1100 and 1200 mm.
How deep should the trench be?

The depth of the trench will depend on a number of factors in addition to pipe diameter. Other considerations include: location of other services, particularly in urban areas, future change in levels due to road regrading or other civil works, required cover, valve pits etc. The minimum depth of cover recommended is 600 mm provided none of the other considerations require a greater depth. In rocky ground, the trench should be excavated at least 50 mm deeper than required and replaced with compacted bedding as described in Section 9: Backfilling. Where the ground below the bedding is unstable, additional excavation should be made and backfilled as described in Section 9: Backfilling.
Pipes strung with sockets facing direction of laying
Figure 5.2- Multiple stringing of pipes When multiple stringing, groups of pipes should be in line with the trench with their sockets all facing the direction of laying. Groups of pipes should be separated by the distance covered by the number of pipes in the group. See Figure 5.2.
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Trenching. If unsure? Shore!
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7. Bedding
Why Bedding ?
Bedding evenly supports the pipe and protects the external coating. Bedding should be spread evenly along the trench with socket holes or welding stations provided at each joint. The socket holes should be deep enough to stop the socket of the pipe bearing any weight. Welding stations should also be big enough to allow welding and wrapping at welded joints. Lift pipe such that base of pipe is at top of bedding
50mm min Figure 7.1- Bedding layer minimum depth The bedding layer under the pipe should be at least 50 mm thick when compacted See Figure 7.1.
Back hoe
Excavator
Trencher
Figure 6.1- Trench excavation machinery
How to excavate
Usually an excavator or backhoe with bucket attachment is used. Only authorised people should operate this equipment. A trencher may be used if conditions permit. This can be a faster method. See Figure 6.1
Barricades should be used if there is a danger of anybody falling into the trench. Occupation, Health and Safety regulations must be observed.
Bedding in wet or unstable ground

In wet or unstable ground, it may be necessary to dig the trench deeper and backfill with gravel to form a foundation layer. A barrier geotextile material may then be placed over this and the bedding material placed on top. The geotextile material specified will prevent fine sand and soil moving into the spaces between the gravel and subsequent loss of support for the pipe.
How to put bedding into a trench

Bedding is usually put into a trench with a front end loader or backhoe. It should be evenly spread along the trench. See Figure 7.2.
Shoring the trench

It is generally necessary to shore the trench if it is deeper than 1.5 metres. Refer to the relevant authority on safe excavation practice. It may still be necessary to use shoring in trenches less than 1.5 metres deep if there is a risk of trench wall collapse as a result of; poor soil strength, vibration from machinery, use of explosives, placement of spoil adjacent to the trench / and/or materials, or water inflow.
Safety
If working under power lines check with the electricity supply authority and the government safety authority. You may need to; arrange for overhead cables to be diverted or protected with insulating covers, arrange for electricity to be cut off, put up goal post type barriers or, use luffing stops on the machine Remember there is greater sag in power lines on hot days.
Bedding in rock
The trench should be excavated to ensure that there is space for a minimum of 50 mm compacted bedding beneath the pipe and to accommodate appropriate joint stations for welding and reinstatement if required. Figure 7.2- Spreading bedding Bedding should be compacted to ensure a firm, even base for pipe laying.
Allowance for sling withdrawal

Consideration should be given to making a small depression in the bedding where slings used to lift the pipe will come to rest after lowering and jointing. This will allow slings to be withdrawn from under the pipe more easily.
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What to use for bedding

Bedding should be granular material such as sand with no stones or sharp objects. The maximum particle size should not exceed 13.2 mm. If the natural soil is not suitable, bedding should be brought in.
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8. Laying and Jointing

General
The majority of water pipelines are laid below ground. However there are also above ground applications, such as at pumping stations, treatment works, over creeks, along bridges or where the cost of trenching is too expensive. Work is often carried out in congested conditions. Observe good housekeeping and safe working practices to avoid injury. Inspect all lifting and pulling equipment regularly for signs of wear and deterioration. All occupational health and safety requirements, including confined space legislation, should be complied with and take precedence over working methods recommended herein.
Joint Types
A number of common jointing configurations are available for steel pipe: Rubber ring joint, SINTAJOINT Expanded and collapsed or spherical slip-in welded joint, Ball and socket welded joint, Butt welded joint Butt welded joint with band or collar Flanged joint See Figure 8.1 SINTAKOTE pipes and fittings are factory formed/assembled for site installation without further site adjustment. Where, as a result of site conditions or damage to pipe, pipes must be cut to length on site, the following should be noted: Pipes with welded joints can be cut and joints welded in accordance with this Section. Pipe ends to be joined should be prepared in accordance with site welding procedure and joint areas reinstated in accordance with Appendices A and B, SINTAJOINT pipe, where cut, can only be joined by welding in accordance with above. Do not attempt to use a cut end in a rubber ring joint. SINTAPIPE pipe should not be cut for jointing. Normally design is carried out to avoid the need for cutting on site. Where SINTAKOTE pipe with welded joint, SINTAJOINT or SINTAPIPE is to be cut and installed with a free end in a corrosive situation, such as in sewer manholes, it is recommended that a Tyco Water representative is consulted.
Jointing Equipment
Anchor sling
Reversed eye, synthetic webbing slings or round slings (of endless fibre construction) are recommended for use in the assembly of SINTAJOINT pipes. Woven synthetic slings must be sheathed to prevent penetration of the fabric by grit, abrasion and deterioration. The slings are fitted to the pipe using a choker hitch and in this configuration the sling is rated to the SWL limit marked on the webbing. See Figure 8.2. Assembly forces will vary depending on the relative dimensions of the ends being joined, and to a lesser extent, the diameter and wall thickness of the pipe. It is expected that these forces would be between 20 and 50 kN. The length of the sling is generally pipe circumference plus 400 mm.
After assembly Figure 8.2- Pulling SINTAJOINT pipes home to joint
Inspection of Pipe Before Laying

General
All pipes are factory inspected, however, damage may occur in handling, transport or site storage. Pipes must be reinspected on site before laying. The inspection should include pipe coating and lining and pay particular attention to pipe ends on SINTAJOINT pipes.
Spherical slip-on joint
Ball and socket joint
Puller
A winch block of 30-50kN pulling capacity fitted with hooks on both ends is adequate.
Rubber mats
Typically 500 x 500 x 6 12 mm thick pieces of conveyor belt or similar should be placed between equipment and pipe where the coating is likely to be damaged during joint assembly.
Plain butt joint
Butt joint with collar
Pipe ends
Pipe ends must be inspected visually for any damage that may have occurred during transport, site storage or handling.
Rags
To clean sockets and spigots immediately before joint assembly.
SINTAKOTE at pipe ends

Should the coating or lining of the pipe ends (socket or spigot end) be damaged, it must be repaired in an approved manner
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SINTAJOINT
Common flange joint
Figure 8.1- Jointing systems
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before the pipe is laid. See Appendix A for methods of assessment of damage to SINTAKOTE and methods of repair .
leaving the manufacturer. Damaged rings must not be used.
Lubricant
Inspect lubricant tins for damage and replace if contaminated. Use only the lubricant supplied by Tyco Water.
Testing of SINTAKOTE
All surfaces coated with SINTAKOTE are factory tested for pin holes and other defects. SINTAKOTE is a tough coating with a high resistance to handling and transport damage. However coating damage can occur through poor handling or incorrect storage. To ensure that the highest quality coating system is placed in the ground, it is recommended that field high voltage holiday inspection be carried out on all coated surfaces. SINTAKOTE can be tested at high voltage without any detrimental effect on coating properties. The voltage for the testing should be set at 12,000V -14,000V and testing undertaken in accordance with AS3894.1 or AS4321 Fusion-bonded medium-density polyethylene coating & lining for pipes and fittings. Note that the safety procedures detailed in the Standard must be strictly followed. With SINTAJOINT pipes, the earth should be clamped to a metal plate, laid on the cement mortar lining. The 12,000V-14,000V test voltage is specified for all coating and lining thicknesses. For SINTAPIPE pipes, ie. pipes that are totally coated and lined with Sintakote, the method specified in AS4321 shall be used.
The recommended method for joint assembly is to pull the pipe being laid into the socket of the previously laid pipe, using anchor slings and winch blocks or pullers. See Figure 8.2. Another joint assembly method is easing the pipe into the joint by slewing the excavator or crane. This method is acceptable, provided it does no damage to the pipe, including the external coating or internal lining. The slewing action must be controlled to ensure alignment of the pipe. Care must be taken not to drive the spigot past the witness mark as this may damage the coating and/or lining. If the pipe is to be cathodically protected, it will be supplied with cathodic protection lugs on both the socket and spigot. Ensure the pipe is installed with these located at the very top of the pipe, to enable connection of joining cable across the joint.
Laying and Jointing of Pipe

SINTAJOINT pipe
The laying of SINTAJOINT (RRJ) pipes is simple and very high laying rates can be achieved. The equipment is inexpensive, light and easily handled. To ensure high laying rates and watertight joints, attention to detail and the following recommended laying practices are essential. The guidelines below are additional to other good practices which should be observed when preparing a trench, storing and laying steel pipes and backfilling. The pipe is manufactured to close tolerances assuring a consistent joint profile. The rubber rings are also supplied to a strict specification, for dimensions, hardness and formulation. These features produce joints with assembly properties easily recognised by the laying team. The ease of spigot entry and the jointing force are so consistent that the laying crew quickly identifies any significant variation. An additional check for correct joint assembly can then be made.
Figure 8.3- Fitting rubber rings into sockets
first placed in the invert and then inserted into the groove by progressively placing it and compressing until the last part snaps in the groove. See Figure 8.3 The ring is slightly over length and this must be evenly distributed by pre-compressing the rubber progressively as it is fitted into the groove. A simple clamp can A simple clamp can assist with holding the ring firm allowing two hands free to fit the balance of the ring. The placement of rubber rings in pipes larger then 1000mm OD may require two people.
Preparation
Start with the free socket end of the previous assembly which should be sitting over a scooped out area of bedding. Measure out the location where the next socket end will fall in the trench, and scoop out the bedding so that after laying there will be sufficient clearance for the socket. Fit the anchor sling behind the socket.
Lubrication
Lift the next pipe and fit an anchor sling over the spigot positioning it about 2 metres from the end. Clean the spigot while it is suspended in the slings. On the spigot, the lubricant should be sparingly applied to the area from the spigot end to the witness mark, providing 100% cover. Lubricate the internal socket lip, the rubber ring and the spigot end of the pipe to be inserted. Use only lubricant supplied by Tyco Water suitable for use with SINTAKOTE pipe.
Rubber ring
Clean the inside of the socket with a clean rag, then fit the rubber ring. Always inspect the rubber ring for damage or tears prior to inserting in the socket. The rubber ring is
Rubber rings
The rings must be visually inspected for any damage which may have occurred after
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Pipe size OD (mm) Experience has shown that this is a critical aspect of rubber ring joint field assembly procedures. Using an incorrect lubricant may cause failure of the rubber ring or SINTAKOTE. The lubricant must cover every exposed part of the internal surface of the socket lip and rubber ring. Unlubricated areas can cause the rubber ring to be displaced from the groove. Care should be taken to ensure lubricant does not get behind or under the rubber ring. High temperatures may cause the lubricant to lose its consistency and become very fluid. Only lubricate the spigot end when operating in high temperatures. High temperatures may also cause premature drying of the lubricant after application. Lubricant should therefore be applied immediately before jointing the pipes In cold conditions it may be necessary to warm the lubricant to a brushable consistency by standing the lubricant container in warm water.
Max permissible misalignment (degrees) 6m
Max permissible offset (mm) pipe length (m) 9m 75 40 12m 100 50 13.5m 112 56
Joint assembly with puller

Align the pipe with the previously laid pipe. This alignment is necessary to ensure that the rubber ring is not displaced from its seat during joint assembly. See Figure 8.4. Where field conditions prevent straight axial entry the spigot can still be entered with a maximum deflection shown in Table 8.1. Jointing will be easier with smaller deflection. Hook on the puller between the anchor slings, and before applying the pulling force, place protective mats under the puller and hooks to prevent damage to the coating. Carefully pull joint into full entry position. The witness mark should be visible and inline with the face of the socket. less than 813 813 or larger 0.5 0.25
50 25
Table 8.1 - Permissible misalignment of offsets during entry When in line with the witness mark, hold in position for a moment to allow the rubber ring to go back to its original profile. Failure to do so will result in the pipe popping back. Do not over engage to compensate for this. The final entry position for undeflected joints is ideally at the line with a tolerance of 5mm. Insufficient entry that exposes the line by more than 5mm after relaxation could result in a leaking joint (Note that when the pipe is deflected, the entry line may be exposed by up to a maximum of 25mm). Entry greater than the line will not lead to a leaking joint but may prevent deflection of the joint. In addition, if entered the full amount, this may result in damage to the spigot end if the pipe bottoms. With the puller load on, deflect the pipe to the required grade and direction on the sand bedding. from under bedded pipes to avoid damage to the SINTAKOTE from sling eyes or hooks. See Section 7: Bedding; Allowance for sling withdrawal.
Important note for concave changes in direction

To satisfy the requirement that rubber ring joints be assembled with the pipes axially aligned, the free end of a pipe just laid in a concave trench must be raised, so increasing the deflection of the previously assembled joint. The joint design allows for this temporary over deflection which, must not exceed the limits shown on the joint drawing. See also Figure 8.5. Similar remarks apply when laying pipes on changes in direction. This temporary over deflection in concave changes in grade is achieved by lifting the pipe end and placing a padded packer (a bag filled with sand or sawdust) under it. After completion of the next joint assembly the packer is removed to allow the pipe to rest back on the bedding. The packer is then transferred to the free end of the pipe just laid and the operation is repeated.
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Figure 8.4 - Alignment of pipes during jointing
The maximum permanent deflections for SINTAJOINT pipes are shown on Figure 8.5. Please Note: If more precise figures are required, please contact a Tyco Water Regional Marketing Office. The puller load must not be released until sufficient backfill is placed around the pipe to ensure that joint movement will not occur. Care should be taken when withdrawing slings
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1700 1600 Temporary construction deflection 1500 1400 1300 400 1200 1100 D. Outside diameter in millimetres 1000 Permanent deflection 900 800 700 600 500 400 300 200 Remove the pipe handling sling and if the pipe is laid on a down grade, place a quantity of backfill over the middle part of the pipe and also compact backfill at the sides to stop joint separation. The placement of the backfill for pipes negotiating concave changes in grade, or 300 200
L L
I
800 700 600

L
I I I I I I I
L
500
L L L
L
L
I
100 0
N
N
0.50
1.00
1.50
2.00
2.50
3.00
Deflection Angle (degrees)

N
6m
9m
12m
13.5m
Figure 8.6 Axial offest measurement created by joint deflection. During this operation, to ensure that the over deflected joint does not come apart, it will be necessary to leave the puller load on at the joint and use a second puller to assemble the new joint. After removal of the temporary overdeflection, place a quantity of backfill over the pipe before releasing the puller load. changes in grade, or changes in direction, must be delayed until the assembly as described above is completed. Remove pulling gear and prepare for jointing the next pipe.
Inspection of assembled joint

By observing the required pulling force and ease of spigot entry up to the witness mark, laying teams quickly develop the skill to assess correct joint assembly. These assessments are generally very reliable, however correct assembly should be verified by inspection. The following inspection methods are recommended to check that each joint is correctly assembled.
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2.5 2 1.5 1 0.5 Deflection angle in degrees Figure 8.5- Temporary construction and permanent SINTAJOINT deflection.
3.5
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External check (see Figure 8.7)

Gap: Visual inspection of the gap between the lip of the socket and the spigot end surface. It should be uniform and in the range 01.5mm. Entry: Entry witness marks applied by the manufacturer and those applied during laying are to confirm entry is correct and no disassembly movement has occurred after laying.
pipe using appropriate lighting, must be performed on each joint. Telescopic or video equipment may be used. This procedure should detect most instances of rubber ring displacement. Joints indicating rubber ring displacement or excessive gapping must be pulled apart, cleaned of all lubricant and re-assembled using a new rubber ring. 2. Lower onto bed to give correct entry and complete weld.
Summary of Important Points for Laying and Jointing: SINTAJOINT Pipes

Use recommended assembly equipment and a method which allows the laying team to develop a feel for correct joint assembly. Use light gear which can be handled easily. Figure 8.7- External inspection of assembled SINTAJOINT Use protection for the coating if there is any possibility it could be damaged by equipment. Inspect the pipe ends for damage before assembly. Inspect the joint and rubber ring. Ensure they are clean and lubricate them correctly just before the assembly. Use the correct joint assembly procedures. Inspect the assembled joint to confirm successful and correct spigot entry. If movement of the assembled joint is possible, take appropriate precautions. Only lubricants specifically recommended for use with SINTAKOTE should come in contact with the coating. Be sure the laying crew have a current drawing of the joint as supplied for the contract. Figure 8.8- Welded ball and socket or slip-in joint field assembly
Welded joints
When welding, ensure adequate ventilation to draw off welding fumes. Clean the ends of the pipe with a wire brush or power brush to remove surface rust etc. Lay pipes with sockets facing the direction of laying. Its easier to locate a pipe spigot correctly into a socket than a socket over a spigot. There is also less chance of entrapping soil in the joint as the spigot is pushed home. Pick up the pipe, refer Section 3: Unloading and handling. Lower the pipe into the trench and insert the spigot end into the socket. The pipe should be inserted angled slightly down toward the spigot. The top of the joint is then tack welded and the pipe lowered onto the bedding to give correct entry. See Figure 8.8. The maximum allowable deflection for slip-in joints is in the range 20 to 30. For ball and socket welded joints, the maximum allowable deflection is 30.
In general, only a single fillet weld is required for sealing and structural purposes. Pipe sizes 813 mm OD and larger may require a seal weld internally to allow an air leak tightness test of the weld. The gap between cement mortar linings at joints should be filled with cement mortar for pipe sizes 813 mm OD and larger. Refer Appendix B - Repair of cement mortar linings and reinstatement of field joints. For smaller sizes, design should ensure joint configurations which permit cement linings to abut. Provide external coating at all joints using a heat shrink sleeve (preferred) or tape field joint coating systems. Refer Appendix A: Field repair and joint reinstatement of SINTAKOTE. Where a SINTAKOTE pipe is cut for welding, the pipe should be stripped back to the steel for a minimum distance of 75 mm each side of the weld.
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Internal check
When regulations and pipe sizes allow entry to the pipe, the assembled joint should be inspected from inside the pipe. This inspection gives the assurance that the rubber ring remains properly seated in its groove. It must be ensured that no part of the rubber ring protrudes past the spigot end of the pipe. On smaller pipe lengths, where access is not practicable, inspection from the end of the
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Maximum Operating Pressure MPa 1.6 3.5
Maximum Temperature C 50 80
Gasket Composition
Solid EPDM Rubber 3mm thick Composit Fibre 1.5mm thick
Table 8.2 - Recommended gasket composition for transport of general domestic liquids including brine and sewage Fig 8.9 Raised face type flanges Fig 8.10 Matched o-ring type flanges Where it is not possible or desirable to use o-ring type flanges, Tyco Water recommends the use of raised face steel flanges. See Figure 8.9. The use of flat-faced steel flanges is not preferred except when the mating flange is cast iron. This situation may occur at a pump housing, but current practice is for most pipeline components to be manufactured in steel or ductile iron. Experience has shown that flat-faced flanges are generally more susceptible to sealing problems and successful sealing is heavily dependent upon assembly technique. Where the required flange sizes are larger than DN 1200 or are outside the normal pressure rating, special flanges must be designed. In this situation o-ring type flanges are recommended as being the best option for medium to high pressure situations. high strength bolts because of the higher initial compression necessary. Table 8.2 details the recommended type of gasket to be used for various classes of raised face steel flanges. Generally full face gaskets (that incorporate holes for the flange bolts) can be used with raised face flanges as only the raised face area inside the bolt holes is clamped. The full face gasket enables better location of the gasket compared to a ring type gasket. (If rigid compressed fibre type gaskets are used the use of ring type gaskets is normal) For other liquids, temperatures or pressures contact a Tyco Water Regional Marketing Office.
Flanged joints
Flanged joints are completely rigid and should not be used for applications where movement of the pipeline is expected, unless special provision is made to accommodate it by, for example, the inclusion of expansion joints. Flanged joints are used mainly for above ground applications, e.g. pumping stations, water and sewage treatment plants and for industrial pipework. They are also used to facilitate the installation and removal of valves in SINTAJOINT and welded pipelines and for valve bypass arrangements. For assembly of flanged joints no field welding or other special equipment is required. Flange dimensions are normally in accordance with AS 4087 and are currently supplied in Class 14, Class 21 or Class 35. For access covers and other blank flange joints Tyco Water recommends the use of o-ring type gaskets because of their low requirement for assembly stress and trouble free operation. O-ring flanged joints have
these same advantages in other flanged joint situations but it must be remembered that the use of o-ring type flanges requires full knowledge of all of the mating components to avoid a joint situation with two o-ring groove ends joining each other. The correct matching is shown in Figure 8.10.
12 8 4 14 10 6
16
5 9 13 3 7
Flange bolts and assembly torque

Bolting used on flanges is usually galvanised steel or stainless steel. Commercial grade bolts are used with the Class 14 flanges and rubber gaskets while high strength studs and nuts are required for use with compressed fibre gaskets. Poor assembly technique is by far the greatest single cause of flange joint failure and use of the correct technique and selection of the suitable bolt torque is vital. Table 8.3, 8.4 or 8.5 may be used as a guide for determining the final torque setting for any flange within the specified range.
Gaskets
Gaskets may be either elastomeric or compressed fibre type. Elastomeric gaskets are only recommended for the Class 16 flanges. Compressed fibre gaskets are recommended for Class 21 and Class 35 flanges. Compressed fibre gaskets can also be used with Class 16 flanges but will require the use of
11 15
Figure 8.12 Star pattern tightening sequence
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TABLE 8.3 Recommended Bolt Torques for Raised Face Steel Flanges Class 16 with Compressed Fibre Gaskets
Gasket - Full Face 1.5mm TEADIT NA1000 Compressed Fibre. Grade 8.8 Galvanised Steel Studs and Nuts, or Stainless Steel Studs and Nuts, Property class 80 Estimated Torque Lightly Oiled Galvanised, or Flange DN Pipe OD No. of Bolts mm 100 150 200 225 250 300 350 375 400 450 500 600 700 750 800 900 1000 1200 114 168 178, 190, 219 235, 240 257, 273 290, 305, 324, 337 337, 356 368 406, 419 457 502, 508, 559 610, 648, 660 700, 711, 762 800, 813 813, 889 914, 959, 965, 972 1016, 1035, 1067, 1086 1200, 1219, 1283, 1290 4 8 8 8 8 12 12 12 12 12 16 16 20 20 20 24 24 32 M16 M16 M16 M16 M20 M20 M24 M24 M24 M24 M24 M27 M27 M30 M33 M33 M33 M33 kN 75 75 75 75 95 95 140 140 140 140 140 175 175 210 260 310 260 260 Bolt Size Bolt Tension Well Lubricated Stainless Steel Studs or Bolts k=0.22 Nm 265 265 265 265 420 420 740 740 740 740 740 1040 1040 1390 1890 2255 1890 1890 Well Lubricated Galvanised Steel Studs or Bolts k=0.15 Nm 180 180 180 180 285 285 505 505 505 505 505 710 710 945 1290 1535 1290 1290
TABLE 8.4 Recommended Bolt Torques for Steel Flanges Class 21 with Compressed Fibre Gaskets
Gasket - Full Face 1.5mm TEADIT NA1000 Compressed Fibre for raised face flanges. - Ring type 1.5mm TEADIT NA1000 Compressed Fibre for flat face flanges. Grade 8.8 Galvanised Steel Studs and Nuts, or Stainless Steel Studs and Nuts, Property class 70 Estimated Torque Lightly Oiled Galvanise Flange DN Pipe OD No. of Bolts mm 114 168, 178 190, 219 235, 240, 257 257, 273, 290 305, 324, 337 356, 368 406, 419 419 457, 502, 508 559 610, 648, 660 700, 711,762 800, 813 889 914, 959, 965, 972 1016, 1035, 1067, 1086 1124, 1145, 1200, 1219 1283, 1290 kN 40 75 75 80 80 80 115 115 115 115 115 190 190 190 190 190 190 310 310 Bolt Size Bolt Tension Well Lubricated Stainless Stee l Studs or Bolts k = 0.22 100 150 200 225 250 300 350 375 400 450 500 600 700 750 800 900 1000 1200 1200 8 12 12 12 12 16 16 16 20 20 24 24 24 28 28 32 36 40 40 M16 M20 M20 M24 M24 M24 M27 M27 M27 M30 M30 M33 M33 M33 M33 M36 M36 M39 M39 Nm 145 330 330 425 425 425 685 685 685 760 760 1380 1380 1380 1380 1505 1505 2660 2660 Well Lubricated Galvanised Steel Studs or Bolts k = 0.15 Nm 100 225 225 290 290 290 470 470 470 520 520 945 945 945 945 1030 1030 1815 1815
1. 'Lightly oiled' refers to the application of a good quality lubricating oil and is the usual as received condition of fasteners. 2. 'Well lubricated' refers to the application of molybdenum disulphide or Koprkote grease 3. The estimated torques provided in the table are based on the friction factor (k) indicated. . Where other factors apply, alternative torques should be calculated. 4. Required bolt tensions and estimated torques have been assumed using established engineering principles. However, variation in installation procedures may result in different requirements.
5. Common pipe sizes not included are 1124, 1145 For these sizes, raised face flanges with elastomeric gaskets are not recommended due to either overstressing of the gasket when tightening bolts to achieve gasket sealing or excessive flange deflection under pressure. If these pipe sizes are used the flanged joints may not be suitable for full test pressure O-ring grooved flanges are more suited to these pipe sizes for Class 16 flanges. 6. Full face flanges not recommended. If used, gasket should be ring type 3mm TEADIT NA1000 Compressed Fibre.
1. 'Lightly oiled' refers to the application of a good quality lubricating oil and is the usual as received condition of fasteners. 2. ' Well lubricated' refers to the application of molybdenum disulphide or Koprkote grease. 3. The estimated torques provided in the table are based on the friction factor (k) indicated. Where other factors apply, alternative torques should be calculated.
4. Required bolt tensions and estimated torques have been assumed using established engineering principles. However, variation in installation procedures may result in differenct requirements.
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TABLE 8.5 Recommended Bolt Torques for Raised Face Steel Flanges Class 35 with Compressed Fibre Gaskets
Gasket - Full Face or Ring type 1.5mm TEADIT NA1000 Compressed Fibre Grade 8.8 Galvanised Steel Studs and Nuts, or Stainless Steel Studs and Nuts, Property class 70 Estimated Torque Lightly Oiled Galvanised, or Flange DN Pipe OD No. of Bolts mm 100 150 200 225 250 300 350 375 400 450 500 600 700 750 800 900 1000 1200 114 168, 178 190, 219 235, 240 257, 273 290, 305, 324 337, 356 368, 406 406, 419 457 502, 508 559, 610, 648 660, 700, 711 762, 800, 813 813 889, 914, 959 1016, 1035, 1067, 1086 1219, 1283, 1290 8 12 12 12 12 16 16 16 20 20 24 24 24 28 28 32 36 40 M16 M20 M20 M24 M24 M24 M27 M27 M27 M30 M30 M33 M33 M33 M33 M36 M36 M39 kN 40 75 75 80 80 80 115 115 115 115 115 190 190 190 190 210 210 300 Bolt Sizes Bolt Well Lubricated
Jointing instructions for flanged joints

1.Use a scraper or wire brush to thoroughly clean the flange faces to be jointed, ensuring there is no dirt, particles or foreign matter, protrusions or coating build-up on the mating surfaces. 2. Ensure that the mating threads of all nuts and bolts are clean and in good condition. 3. Evenly apply a suitable lubricant (e.g. molybdenum disulphide) to all mating threads, including the nut load bearing face and washer. 4. Align the flanges to be joined and ensure that the components are satisfactorily supported to avoid bending stress on the flanged joint during and after assembly. 5. Insert four bolts in locations 1 to 4 as indicated in Figure 8.11 and position the insertion gasket on the bolts, taking care not to damage the gasket surface. 6. Offer the adjoining flange to the bolts, taking care to maintain support and alignment of the components. 7. Tighten nuts to finger tight and check alignment of flange faces and gasket. 8. Insert the remaining bolts and tighten nuts to finger tight. 9. Estimate the required bolt torque considering bolt type and allowable tension, flange type and rating, gasket material and max/min compression, and the pipelines maximum pressure (operating/test pressure). Refer to tables 8.3, 8.4 or 8.5 for recommended torque values. 10. Tighten nuts to 20% of estimated torque using the star pattern; see Figure 8.11.
Well Lubricated Galvanised Steel Studs or Bolts k=0.15 Nm 100 225 225 290 290 290 470 470 470 520 520 945 945 945 945 1135 1135 1755 Studs or Bolts k=0.22 Nm 145 330 330 425 425 425 685 685 685 760 760 1380 1380 1380 1380 1665 1665 2575
Tension Stainless Steel
11. Tighten to 50% of estimated torque using the same tightening sequence. 12. Tighten to 75% of estimated torque using the same tightening sequence. 13. Tighten to 100% of estimated torque using the same tightening sequence. 14. Repeat the tightening procedure on all nuts until little or no movement can be achieved on each nut. (particularly important on elastomeric gaskets) Grade 8.8 galvanised steel or grade 316 property class 80 stainless steel stud bolts are recommended for use with composite fibre gaskets. Bolt tensions need to counter the force due to expected internal pressure and to provide an adequate sealing stress without exceeding the maximum allowable gasket stress at the time of installation. The application of excessive torque at the time of installation may overstress the gasket causing crushing or extrusion, which can lead to leakage at operating pressures. The surface conditions of the threads as a result of rust, plating, coating and lubrication are the predominant factors influencing the torque / tension relationship. However, there are many others including thread fit, surface texture and the speed and continuity of tightening. The flange faces are assumed to have a surface roughness of Ra = 10 -12.5 m. A torque wrench is most commonly utilised to achieve the required bolt tension, however in critical applications an hydraulic tensioner should be used.
1. 'Lightly oiled' refers to the application of a good quality lubricating oil and is the usual as received condition of fasteners. 2. 'Well lubricated' refers to the application of molybdenum disulphide or Koprkote grease. 3. The estimated torques provided in the table are based on the friction factor (k) indicated. Where other factors apply, alternative torques should be calculated.
4. Required bolt tensions and estimated torques have been assumed using established engineering principles. However, variation in installation procedures may result in different requirements.
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9. Backfilling
The materials used for backfilling the trench and their compaction should be specified by the designer. Proper support and protection of the pipe should be considered together with the future ground loading and activity. For small diameter pipe laid in an area where surface settlement is not a problem, minimum backfill compaction is normally adequate. However as the depth of cover increases or where vehicle traffic occurs, and especially for large diameter thin wall pipes, the degree of compaction becomes critical to ensure the long term performance of the pipeline.
Zone A - Bedding
A minimum 50 mm thick compacted bedding layer of sand, non cohesive native soil or imported fill (100% less than 13.2mm) should be provided under the pipe as bedding. Bedding material may need to be imported or may be present after excavation. Bedding provides even support for the pipe along its entire length and protects the SINTAKOTE.
The degree of compaction required will depend on the loading for which the pipeline has been designed and the ring stiffness of the pipe. Ring stiffness depends on the pipe wall thickness and diameter; a thick walled small diameter pipe is stiffer than a thin walled large diameter pipe. An indication of stiffness can be taken from the diameter/steel wall thickness ratio or D/t. For steel pipes equal to or less than 914mm OD, with a D/t less than 120, only moderate compaction is required to achieve the necessary support. Pipes with D/t values greater than 120, or greater than 914 mm OD, need more support from the side fill to carry the soil and traffic loads and the level of compaction specified should reflect this. When high levels of compaction are specified for these low stiffness pipes, it is essential that backfill be well compacted between the sides of the pipe and the trench. Particular care should be taken in compacting the material under the haunches of the pipe. The backfill should be built up in 150 mm layers evenly on both sides of the pipe. Backfilling in layers should proceed until there is an overlay of at least 150 mm above the top of the pipe. This layer provides a zone of material to prevent sharp objects imparting
high point loads on the coating. When a pipeline is to be cathodically protected, material should not be too high in electrical resistivity as this will reduce the effectiveness of the protection. Generally sand or soil is suitable. Stone and gravel can be too high in resistivity. Hence a well graded mix of sand and gravel should be used on cathodically protected lines where imported backfill is required.
Zone B - Backfill for haunch support, side support and overlay

The haunch and side support areas provide support for the pipeline and prevent sharp objects imparting high loads onto the pipeline coating. Backfill should consist of non-cohesive native soil, free from stones and sharp objects larger than 25 mm or imported fill, sand or rounded gravel not greater than 20mm.
Zone C - Overburden trench fill

Material in this zone builds the trench up to the original ground level and the materials used and extent of compaction depends on the allowable future surface settlement. Under road pavements the load bearing capacity of the ground surface is important and backfill must be compacted in layers all the way to the surface. Where the trench is across open land, the compaction requirements of this zone are not normally so important and the surface can usually be built up to allow for some future settlement. The material used in Zone C, would normally be the excavated trench material, but where a high degree of compaction is needed in bad natural ground, imported material may be required.
Zones of backfill and compaction

The soil surrounding the pipe can be considered as three Zones shown in Figure 9.1.
ZONE C
600mm min
150 to 300mm ZONE B ZONE A 50mm min under pipe barrel Figure 9.1- Zones of backfill and compaction
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10. Fittings
Compaction
The level of compaction to achieve in-situ ground conditions, may require 65% Relative Density for sand or 90% Standard Proctor Density for clay type (cohesive) soils. Soil density is usually specified as Standard Proctor Density for clay type soils and Relative Density for granular soils (cohensionless). Standard tests are available for determining the density of compacted soils. During construction these limits may need to be lowered where service loads contribute significantly to ring deflection.
Sintajoint (RRJ)
For SINTAJOINT pipe a safe service ring deflection limit of 2% of the pipe OD is recommended. This is to ensure that the annular gap between spigot and socket is not so distorted as to cause significant reductions in gasket contact pressure.
Concentric Reducer
Mitred Bend 0 to 22.5
Mitred Bend 22.5 to 45
Mitred Bend 45 to 90
Eccentric Reducer
Tee
Angle Branch
Y-Piece
Welded Joints
For pipes with welded joints and cement mortar lining, a safe service ring deflection limit of 3% of the pipe OD is recommended. This is to avoid possible repetitive flexing of the pipe and fraying of the lining.
Figure 10.1- Common Fittings - welded pipelines Note that Tees, Angle Branches and Y-Pieces may require reinforcing as indicated. Good planning at the design stage can result in improved installation efficiency. This is particularly true for pipelines requiring numerous fittings. For fully welded lines, fittings should be ordered to suit and can be fabricated from SINTAKOTE pipe. For rubber ring joint pipelines, consideration needs to be given to anchorage at change in direction, dead ends, tapers or tees. See Section 11: Anchorage of pipelines. For rubber ring pipe joints under maximum allowable deflection (see Figure 8.6) thorough compaction of the embedment zone on the outside of the joint is required. For directional changes greater than that achieved by deflection of a pipe joint, fittings are required. For common use fittings see Figures 10.1 and 10.2.
Ring deflection limits

To ensure serviceability of the pipeline, ring deflection must be limited as described below and shown in Figure 9.2.
= % OD Maximum deflections RRJ: 2% Welded joint: 3% Note: Vertical deflection shown left is greatly exaggerated for clarity of terms
Hockey Stick
Bedding reaction Pipe section before backfill and compaction Pipe section after backfill and compaction loading
1 metre short Figure 9.2- Ring deflection limits
Mitred Bend
Tee Reducer Air valve or Scour Flanged Offtake Figure 10.2- Common Fittings - SINTAJOINT pipelines Note that reducers may require a thrust flange.
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Fatigue it does happen? Obey the site rules
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11. Anchorage of Pipelines

Static thrusts
All pressure pipelines having unanchored flexible joints, require anchorage at changes of direction, changes in diameter, tees, valves and at blank ends to resist the thrusts developed by internal pressure. Additional dynamic thrusts are created by moving water but are usually negligible unless the flow velocity is extremely high. block to ensure that the soil bearing strength does not deteriorate. Where possible concrete anchor blocks should be of such a shape as to allow sufficient space for the joints to be pulled apart, pipe or fittings replaced and reassembled.
Anchor blocks for horizontal thrust-buried mains

The horizontal thrust developed in buried mains must be transferred to the undisturbed soil of the trench wall by anchor blocks poured against the soil face. The thrust is distributed over the total bearing area of the block to ensure that the safe bearing pressure of the trench wall is not exceeded. See Figure 11.1
Anchor block for vertical slope
Anchor block for vertical bend
Figure 11.2- Anchor blocks for vertical thrust restraint Upward vertical thrusts are counteracted by the weight of the concrete anchor block. If the water table in the area is likely to reach the level of the anchor block, the submerged weight of the block must be sufficient to counteract the thrust. If the natural ground is of sufficient strength ie., rock, special anchor blocks can be cast into the rock to resist upward thrust forces. See Figure 11.2
Anchorage of buried mains

Anchorage to resist thrusts must be designed for the maximum pressure expected in the main in service or during test. Anchorage can be provided in several ways: Anchor blocks, Ties to concrete blocks, or Pipe surface friction The most common method is the use of concrete anchor blocks. These should be poured immediately after excavation for the
Pipe surface friction

Thrust resistance can be achieved by utilising the skin friction between the pipe and soil surround. This requires the welding or harnessing of several pipe lengths, the length of which must be determined by the pipeline design engineer.
Anchor blocks for vertical thrust restraint.

Downward vertical thrusts are transferred to the undisturbed ground by anchor blocks in the same manner as horizontal thrusts.
Above ground pipes

For above ground applications all steel pipes must be supported and anchored. Where relative movement of the pipe support and anchorage is likely, the bearing materials should be chosen to allow for this. See Figure 11.3
Ties to concrete blocks

Ties are rarely used except where there is limited space or lack of bearing area behind the pipe fitting. Hold down over bearing material
Anchor block for horizontal bend
Bearing material to accommodate expansion movement where necessary Anchor block for horizontal tee Anchor block for horizontal taper Figure 11.3 - Pier support for above ground SINTAJOINT pipelines
CHAPTER 11
Be aware of your surrounds Be aware of your surrounds
Figure 11.1- Anchor blocks for horizontal thrust restraint
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12. Hydrostatic field test

A pipeline is subjected to a field pressure test primarily to check that all joints are watertight. At the same time the test checks the integrity of all fittings and appurtenances, as well as construction work such as anchorages. It is recommended that a hydrostatic test is carried out on the first 200m of pipe laid to confirm that laying practices are effective. Where concrete anchor blocks are installed, a reasonable time must be allowed for the concrete to cure before testing commences. Cement mortar lined pipe should be completely filled with water of approved quality and allowed to stand for at least 24 hours. This permits maximum absorption of water by the lining and release of any air. Additional water should be added to replace the quantity absorbed. The pipeline should be filled slowly to prevent water hammer and to minimise entrapment of air. If the pipeline section to be tested is not provided with isolation valves then the ends must be fitted with bulkheads. Pipes or bulkheads must be fitted with the necessary outlets for incoming water and outgoing air. The hydrostatic test usually commences after the 24 hour standing period. The water pressure should be raised to the specified field test pressure, such pressure being measured at the lowest point of the section under test. Alternatively a static head allowance may be made between the lowest point and the point of the section under test. See Figure 12.1. Field hydrostatic test pressures are specified by the design Engineer after consideration of the working pressure of the pipeline. The test pressure should be maintained for at least 2 hours. If the pressure has dropped at the end of the test, the volume of water needed to restore the original pressure should be measured. The test should be repeated a number of times with any make-up volume being measured. This make-up volume may result from pipe movement and compression of small quantities of entrapped air. Some leakage may be permitted to accommodate field constructed mechanical joints, and seals on fittings and appurtenances. Allowable make-up rate (L/hr) = -7 1.4 x 10 x D x L x H Where D = Pipe OD (mm), L = Pipeline length (m), H = Average test head(m) If the specified allowable make-up volume is exceeded the following procedure should be followed. Ensure that all air has been expelled and the 24 hour standing period has elapsed. Check all valves for full closure and sealing. Check all mechanical joints, gibaults and flanges. Bolts should be uniformly tight and full sealing achieved. If subsequent testing still results in unacceptable make-up volume, the ground above the line should be inspected for signs of obvious leakage. If none are apparent the line should be tested in halves with the failing section being subsequently halved and tested until the leak is located.
Pipeline section under test
Allowable make-up volume

Any allowable make-up volume should be specified by the designer. A generally accepted make-up volume rate is;
25m static head Location A Test pressure 200m Location B Test pressure 175m
200m test pressure required at Location A Gauge at A should read 200m Gauge at B should read 175m Figure 12.1- Static head allowance for hydrostatic test with alternative pressure gauge locations
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13. Commissioning water pipelines

Prior to commissioning ensure the removal of any solid material from the inside of the pipeline including rubbish, dirt, welding stubs and other foreign matter. This may be achieved by placing a swab or pig through the line or in the case of larger diameter pipes, by operators travelling through the line. Only soft foam swabs (with no scouring pad attachments) should be used on seal coated pipelines. A pipeline which will carry potable water should be sterilised with chlorinated water in accordance with the water authoritys requirements.
APPENDIX A -
Field repair and Joint
Reinstatement of SINTAKOTE
Mild steel cement mortar lined pipe is supplied with SINTAKOTE, a fusion bonded medium density polyethylene coating for welded or rubber ring jointing. Fittings may be fabricated from SINTAKOTE pipe, but are also available as SINTALINK fittings, entirely coated with SINTAKOTE. In order to determine whether or not a damaged area requires repair the following assessment should be made:Continuity test at 12kV. If a holiday is detected then repair. Determine the coating thickness. If less than 1.0 mm then repair. Figure A.1 has been devised to determine the best method for field repair of SINTAKOTE for buried service at ambient temperature. Heat
Is repair a welded field joint?
shrink sleeves are the preferred method of protection of field welds. Enclosed are the procedures for heat shrink sleeve coating (A1), tape wrap coating (A2), adhesive patch repair (A3), Drader gun welding repair (A4) and SINTAPIPE end repairs (A5). The use of petrolatum tape protection systems is not recommended for the repair or field joint coating of SINTAKOTE. This is primarily due to their very poor resistance to soil stresses. The techniques detailed in this Appendix do not apply to pipelines operating at temperatures above 30 0C, nor do they apply to piles/pipelines used in above ground situations. For repair/joint coating of these pipes contact Tyco Water.
YES
Choose either heat shrink sleeve (preferred) or tape wrap field joint coating
NO
Is repair away from SINTAJOINT ends?
YES
Is repair area >10,000mm2? (100 x 100mm)
YES
Choose either heat shrink sleeve (preferred) or tape wrap field joint coating
NO Repair is at SINTAJOINT ends, use Drader welding repair method
NO Use either adhesive patch, heat shrink sleeve or tape wrap coating method
Figure A.1 - Flow chart for determining appropriate SINTAKOTE repair method
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Procedure A1 -
Heat Shrink Sleeve Coating Method

of the shrink sleeve manufacturer. 4. Using 120 grit emery or sandpaper slightly roughen the SINTAKOTE around the repair for a minimum distance of 100 mm from the edge of the repair. Solvent wipe the SINTAKOTE with a clean cloth (isopropanol is a suitable solvent for cleaning). 5. Apply the shrink sleeve in accordance with the application procedures of the manufacture. If preheating cannot be achieved, brush apply a thin film of primer to any steel not coated with SINTAKOTE and onto the SINTAKOTE for a distance of 100 mm. Do not apply the primer prior to preheating. Ensure that the sleeve overlaps the SINTAKOTE for a minimum width of 100 mm. Note that the specified preheat and postheat is necessary to ensure satisfactory bonding of the sleeve. A roller should be used to eliminate voids from under the sleeve. 6. The repair should be visually inspected to ensure that it is in intimate contact with the pipe and that a bead of mastic has exuded from each end of the sleeve for the full pipe circumference. (If this is not in evidence additional heating is required).
Procedure A2 -
Tape Wrap Coating Method

roughen the SINTAKOTE for 100 mm from the edge of the repair using 120 grit emery. The steel and coating area should be clean and dry before application of the primer.
The application of heat shrink sleeves will give the optimum field protection. However, personnel applying sleeves need to be fully trained and experienced.
Recommended Sleeves
The recommended sleeves are: 1. Raychem WPCB available from Petro Coating Systems Pty. Ltd. The primer is Petrocote primer. 2. CANUSA KLS available from Denso Pty Ltd. The primer is Denso Primer.D.
This tape system provides a thick coating repair or field joint coating with similar impact resistance to that of SINTAKOTE. Thinner coating systems may not provide the same degree of protection. The outerwrap of a thin PVC tape is provided to reduce soil stresses as far as is possible with a tape wrap system. A heat shrink sleeve repair/joint protection is recommended for optimum resistance to soil stresses.
Procedure
1. Cut out a piece of tape (Ultraflex 1500) to fit into the bare steel area. (This is used for repair, it is not necessary for field joint coating). 2. Using a brush, apply a thin even coat of primer onto the steel and onto the SINTAKOTE by 100 mm. 3. Allow the primer to tack dry (approx. 10mins). Insert into the repair the cut piece of tape. 4. Spirally apply the tape (Ultraflex 1500) to the repair area ensuring a 100 mm overlap onto the SINTAKOTE. The overlap of tape layers should not be less than 55% of tape width. 5. Spirally apply the outerwrap (Denso MP/HD) to completely cover the first layer of tape coating. The overlap of layers should not be less than 10% of the overwrap width. 6. Some tension should be applied when applying the tapes to ensure that air voids, wrinkles etc. are not present after wrapping.
Recommended tape wrap

The following tape system or equivalent is recommended:Primer - Denso Densolen HT primer or Denso Primer D. Primary tape - Denso Ultraflex 1500 tape with a minimum 55% overlap. Secondary tape - Denso MP/HD tape with a minimum 10% overlap. These products are available from Denso (Aust.) Ltd.
Application procedure
1. Bevel the edges of the SINTAKOTE so that there is a tapered transition of at least 5 mm between the full coating thickness and the exposed steel. 2. Remove any corrosion products on the steel and abrade the steel surface (if necessary) to produce a clean, noncorroded, roughened surface. Suitable abrasives are emery paper or a steel file. 3. Prepare the area to be repaired (to be free from dirt, dust and other contaminates) in accordance with the recommendations
Application procedure
The method of application should be in accordance with the tape manufacturers recommended procedures with the following additions:-
Preparation
Use a knife to remove all burrs/stubs from the parent coating. For coating repair, slightly
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Procedure A3 -
Adhesive patch repair method
Drader welding repair method (for field repair at SINTAJOINT pipe ends only)
Jointing Region 200mm
Jointing Region
Procedure A4 -
This method is recommended for repair areas up to 10,000 mm2 (ie 100 x 100 mm). It is only recommended for field use. The method uses a mastic filler, a heat fused repair patch and an overwrap tape. The tape overwrap is provided to reduce the effect of soil stresses on the patch coating. A heat shrink sleeve coating is recommended for optimum resistance to soil stresses (see A1). Note that rolls of Perp material should not be left in the sun as the product can heat up and cause the layers in a roll to fuse together.
with a clean cloth (acetone and isopropanol are a suitable solvents for cleaning). 4. Preheat the entire region to be covered by the patch (including the exposed bare metal), to a minimum temperature of 600C, with a yellow flame from a propane/air gas torch. The temperature can be measured with a melt stick. 5. Place a pre-cut piece of Perpfiller to cover the area of exposed steel. Heat the mastic and smooth it with a flame heated paint scraper type blade to cover all bare metal and to exclude all air. Do not smear the mastic over the SINTAKOTE. Any excess mastic Recommended Materials should be removed so that the mastic just fills the damaged region. The following system or equivalent is 6. Apply a yellow flame to the SINTAKOTE to recommended: warm the surface. Filler - Raycem Perpfiller 7. Apply a yellow flame to the adhesive side Patch - Raychem Perp of the Perp until it appears glossy. Overwrap - PCS PVC250 overwrap 8. Immediately apply the patch to the Products available from Petro Coating Systems. damaged area centering the Perp with respect to the damage. Application Procedure 9. Heat, using the gas torch, from the centre Recommended adhesive repair patches of the Perp, and use rubber coated or Teflon 1. Clean and dry the area to be repaired (free roller to eliminate any entrapped air. Continue from dirt, dust and other contaminates). At all heating and rolling until adhesive is observed the coating interfaces with bare steel, the exuding from all areas of the Perp. coating must be bevelled to an angle of 300 10.Ensure the area to be tape wrapped is to the steel. clean and free from any dirt/contamination. 2. Cut a patch from the Perp roll big enough If in doubt, solvent wipe. to extend 80mm beyond the damaged area on 11.Spirally apply the Denso MP/HD tape all sides. The corners of the Perp patch should around the full circumference of the pipe, with be rounded to at least a 30mm diameter. tension applied, to completely cover the patch 3. Slightly roughen the SINTAKOTE around repair and overlap it by at least 80mm on all the repair for a minimum distance of 80 mm sides. The tape overlap should not be less from the edge of the coating damage, using than 10% of the tape width. 120 grit emery. Solvent wipe the SINTAKOTE
Welding equipment
1. Drader extrusion welder and suitable welding tips. Refer Figure A.3 & A.4. 2. 240 V extension lead and power supply 3. Air supply 550 to 700 kPa (80 to 100 psi) 4. Thick leather gloves 5. Wraparound tip
Figure A.2 - Joint Region for Drader welding repair
Materials
1. A 4 mm nominal diameter extruded medium density polyethylene filler rod supplied by Tyco Water. (SINTAKOTE filler rod). 2. Clean cotton rags and isopropanol cleaning solution.
For use only where damaged SINTAKOTE surfaces occur in the jointing region shown in Figure A2. The Shrink Sleeve method or Adhesive Patch method should be used where damage occurs away from the joint region. This method is the only approved method for repairing the spigot end and socket end of SINTAJOINT pipe or fittings. When properly executed, this method will ensure good fusion between the filler material and existing SINTAKOTE.
General Instructions
1. The Drader Injectiweld can produce sound weld deposits of various shapes that are effectively bonded to the original surface provided the correct technique is used. 2. Temperature setting The welder unit should be preset to 270C initially and no further adjustment is necessary. 3. Select the correct tip and fit to the gun as follows: Remove the retaining nut with the tool provided. This will require the gun to be switched on and heated up for a few minutes. Remove the previous tip being careful to locate the aluminium washer that is fitted between the tip and the body of the gun. 4. Figure A.3 shows the gun with tip removed. Always replace the washer: Failure to replace the washer before fitting the new tip will allow extruded material to be forced down these holes and possibly damage the heater and/or sensor.
APPENDIX A
Qualifications
Each operator who is to make repair welds upon coatings should be suitably practised and should be able to achieve adequate fusion in practice welds. Such welds can be evaluated by removing full thickness sections perpendicular to the weld. These sections can then be bent one way and then the other, through an angle of approximately 30 0, to place the internal and external surfaces of the coating in tension. Any lack of fusion indicate an unsatisfactory weld.
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Barrel
Heater Aluminium Washer Sensor Indexing Pin
for several seconds until a quantity of plastic extrudes out of the end of the tip. Adjust the feed rate to give a moderate flow (no more than 2 pulses per second has been found to give good results). Remove the extrudate with a knife or suitable tool. Figure A.4 - Drader gun tip selection If there is a split in the coating away from the end of the pipe this should be first repaired with a butt weld tip before attempting this repair. Operators who attempt this repair technique should have attended a Sintakote repair training course and be certified as being competent in the use of the equipment. 1. Clean the affected area to ensure that all the dust and foreign matter is removed from the repair area. Use a file or knife to remove any coating that may be sticking out. 2. The transition area from full thickness at the start and finish of the defect should be tapered over about 40 mm to enable the tip to travel smoothly without catching on any step. This is best done with a sharp knife or rasp. 3. Fit the Concave tip that suits the pipe wall thickness to the gun. Experience has shown that it is better to fit the tip so that the groove is horizontal when the gun is held out with the handle vertical. This means that the gun travels sideways and gives the operator a better view of the repair area both in front of and behind the weld. 4. Ensure that the heating tip has reached the correct temperature and that the LED is flashing. 5. Test the feed rate by pressing the trigger 6. Determine the line of weld that the repair should be laid along and place the welding tip about one tip length before the transition to the defect. This ensures that any lack of bond on start up is outside the original defect area. The gun should be held so that it remains straight out from the pipe end but angled sideways (about 150) in the direction of the weld as determined by the angle of the tip, keeping the full face of the tip in contact with the end of the pipe at all times. Make certain that the surface beneath the tip begins to melt before commencing the weld. 7. Hold down the trigger and start moving the welder the required direction at a constant speed to ensure smooth feeding of the weld pool. 8. Use a travel speed that will give good build up of material and good coverage of the coating on both sides (see Figure A.5). Failure to get good fusion on either or both sides will result in further more complicated repairs. (Generally good fusion will result when the build up on either side of the end is about the same). If there is still poor fusion then the travel speed is too fast. 9. It is important to complete the line of weld without stopping until the tip is beyond the defect area otherwise a new transition will have to be prepared before restarting repairs.
APPENDIX A
Gun Handle
Figure A.3 Drader gun assembly 5. Apply a small amount of the Heat transfer paste to the top of the washer and the threads of the body to enable them to be easily removed later. Place the gun on a horizontal surface so that it is pointed up and place the tip over the end so that it fits snugly over the washer and pin. Occasionally the tip may not engage correctly because the locating holes are filled of plastic. In this case wait until the tip heats up and melts the plastic in the holes. Ensure that the tip sits firmly on the washer and place the retaining nut over the tip and push it down until it engages the thread (use thick gloves and/or cotton rags to prevent burning hands all of these components will get hot). 6. Never place the tip into the retaining nut first and screw it onto the gun. This could break off the locating pin making it very difficult to repair. 7. Screw the retaining nut up tight with the tool provided. This process may need to be repeated a few times as the components heat up and the retaining nut expands. (It may also be necessary to heat up the gun to replace a tip later).
8. Fit the 4 mm plastic wire into the hole at the base of the gun and rotate the feed nut to engage the wire. The wire should not be able to be pulled out from the gun when correctly engaged. Never operate the feed trigger without plastic wire being engaged. This could result in damage to the feed mechanism.
Various concave tips for wrap around end repair

These specially developed tips are designed to repair the Sintajoint wraparound ends in a single pass. They produce a finished end that generally only needs one side trimmed, (outside of the spigot or inside of the socket) The technique used for the repair of end damage requires a determination of the extent of the damage. Small damage such as punctures or dents might be repaired with a number of tips including the Cone tip, Ball end tip, the 3/16 Fillet weld tip or one of the butt weld tips. Large damage which involve more than 25 mm long repairs to the end will be best repaired with the concave tip that suits the particular plate thickness. These tips are identified as W06 for 6 mm pipe wall thickness, W08 for 8 mm pipe wall thickness etc. The following procedure describes the use of these concave tips.
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Welding tip
It is assumed that the pipe has been cut with a suitable machine and is presented with the coating and lining flush with the end of the pipe. Outside Trim excessive material Figure A.6 Care required when trimming Operators who attempt this repair technique should have attended a Sintakote repair training course and be certified as being competent in the use of the equipment. 1. Clean the affected area with isopropanol to ensure that all the dust and foreign matter is removed. Use a file or knife to remove any coating that may be sticking out. 2. Fit the Concave tip that suits the pipe wall thickness to the gun. Experience has shown that it is better to fit the tip so that the groove is horizontal when the gun is held out with the handle vertical. This means that the gun travels sideways and gives the operator a better view of the repair area both in front of and behind the weld. 3. Ensure that the heating tip has reached the correct temperature (i.e. the LED is flashing.)
the surface beneath the tip begins to melt before commencing the weld. 6. Hold down the trigger and start moving the welder the required direction at a constant speed to ensure smooth feeding of the weld pool. 7. Use a travel speed that will give good build up of material and good coverage of the coating on both sides (see Figure A.5). Failure to get good fusion on either or both sides will result in further more complicated repairs. (Generally good fusion will result when the build up on either side of the end is about the same). If there is still poor fusion then the travel speed is too fast. 8. It is recommended to complete as much welding as possible without stopping as a new transition will have to be prepared for each start. The start area must be feathered back to the surface to remove any unbonded areas and to provide a smooth area for finishing the weld. 9. To complete the run make sure that the bead finishes past the initial start area to ensure a complete seal. 10. When the weld has solidified the excess material can be removed using a suitable tool being careful not to cut below the original surface level (see Figure A.6). 11. Visually examine the finished area for defects and repair if necessary using a suitable tip. 12. Check the repair using a High Voltage Holiday Detector. Repair any defects and retest. The finished end should now be suitable for the attachment of a pipe coupling.
Plastic deposit Figure A.5 Build up of material on cut end 10. When the run is completed angle the gun so that it is perpendicular to the end of the pipe and continue to extrude material as the tip is withdrawn from the surface. This will reduce any plasticised defects caused by the tip. 11. When the weld has solidified the excess material can be removed using a suitable tool, being careful not to cut below the original surface level (see Figure A.6). 12. Remove material from the end in the start and finish zone where double thickness has been applied.
13. Do not remove any material from the end in the defect zone. (Wood rasps and planer can be used for this purpose). It is only necessary to remove excess material from the outside of the spigot. It is better to remove the excess from both the inside (necessary) and outside of the socket to give a better appearance. 14. Visually examine the finished area for defects and repair if necessary using a suitable tip. 15. Check the repair using a High Voltage Holiday Detector. Repair any defects and retest.
Procedure A5 after field cutting Equipment

Refer to Procedure A.4
Wraparound reinstatement of SINTAPIPE
Various concave tips for wrap around end reinstatement

1. Identification Marks W05, W06, W08, W10, W11 etc. for 5,6,8,10 and 11 mm wall thickness pipes. 2. These specially developed tips are designed to reinstate the Sintakote around the end in a single pass. It will produce a sound repair that is bonded to the external and internal coating.
Materials
4. Test the feed rate by pressing the trigger for several seconds until a quantity of plastic extrudes out of the end of the tip. Adjust the feed rate to give a moderate flow (no more than 2 pulses per second has been found to give good results). Remove the extrudate with a knife or suitable tool. 5. The gun should be held so that it remains straight out from the pipe end but angled sideways (about 15) in the direction of the weld as determined by the angle of the tip. Keep the full face of the tip in contact with the end of the pipe at all times. Make certain that
General Instructions
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APPENDIX B
Field Repair and Joint Reinstatement of Cement Mortar Lining
The cement mortar lining of steel pipes in factory production is carried out in accordance with Australian Standard AS 1281- Cement mortar lining of steel pipes and fittings using a centrifugal process. This method ensures a dense, low water cement ratio mortar in close contact with the steel. In the factory all pipes are end capped and held for several days to enable the mortar to cure. Pipe fittings are lined in the factory either using a centrifugal mortar applicator, by hand lining or by a combination of centrifugally lined pipe with the joints reinstated by hand. Lined fittings are end capped and allowed to cure before delivery. In order to determine whether or not the mortar requires repair the following procedure should be followed:1. Use a 2.0 mm feeler gauge and see if it can be inserted to a depth greater than half the thickness of the lining. If it can, the mortar should be repaired as described in B2. 2. Use the feeler gauge to determine if the mortar has disbonded to give a gap in excess of 2 mm between the mortar and the steel pipe. This can be measured by attempting to insert the feeler gauge into the gap (at the ends of pipe) or to check if the step between adjacent sections of the lining (at a crack) is greater than 2 mm. If the disbondment is greater than 2 mm break out the disbonded lining and repair as described in B1. Disbonded (drummy) linings are acceptable provided the above criteria are not exceeded or if potable water is placed inside the pipe and water absorption leads to total loss of the drumminess. Cement mortar lining repairs and pipe joint reinstatement are usually done by hand application of the cement mortar. The procedures detailed herein are summarised as follows:1. Lining repair using premixed materials. 2. Epoxy repair of cement mortar lining cracks.
Procedure B1 -
Cement mortar lining repair method
Using EZILINE Premixed Materials (for field repair/joint reinstatement)

The EZILINE Mortar Mix is a high performance product specifically designed for compatability and use in reinstating the field joints and repair of Tyco Water cement mortar lined steel pipes and fittings.
Application Instructions
1. Ensure all surfaces are free of grease oil, paint and loose or flaking materials.
2. Wet the adjacent mortar, leaving the surface damp, but with no excess/pooled water
Materials
Available from Tyco Water in kit form.

Dry Mix - Part A Type SR blended cement in compliance with AS 3972 and sand in full compliance with AS 2758.1. Liquid - Part B The liquid is a high performance acrylic modifier. Primer - Liquid Part B is used undiluted as the primer. For safe use of the product, refer to the MSDS.
3. Brush apply a primer coat of Part B (liquid) to cover the steel and adjacent mortar. Note do not dilute. The mortar can be applied when this coat is wet or dry, but must be applied the same day, otherwise apply another prime coat. 4. Thoroughly manually mix Part A (do not use a cement mixer) and as much of Part B required to form a stiff workable mixture. Do not add water. Ensure there is no dry mixture present. Note the working time reduces with temperature, and is apporx. 20 minutes at 300C. 5. Apply the mortar, compacting it into place to the level of the adjacent mortar. 6. Finish with a metal trowel to provide a smooth even finish.
7. The mortar should be protected from excessive heat, water and sub-zero temperatures during the first 24 hours from placement. It should be allowed to fully dry/cure for at least 7 days prior to service.
8. Open bags of mortar not used within 24 hours should be discarded thoughtfully. 9. Dispose of packaging and waste material appropriately after use.
APPENDIX B
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S I N T A K O T E
S T E E L
P I P E L I N E S
S I N T A K O T E
S T E E L
P I P E L I N E S
Procedure B2 -
Epoxy repair of cement mortar lining cracks

2. With a spatula or knife applicator press the epoxy into the groove to exclude all air. Slightly overfill as shown in the diagram. Allow to cure for at least 24 hours prior to exposure of the epoxy to water.
APPENDIX C
Field Application of Electrical Cables to CP Lugs
Procedure M a t er ia ls Cable cutter suitable for 25
1. When making the joint make sure that both lugs are aligned as close as possible (Fig 1), preferably, at the top of the pipe.
This method is applicable to repair of cracks in cement mortar lined (CML) pipes. It is used to repair cracks that are greater than the 2.0mm width allowed in AS 1281.
Materials
The following materials are suitable:Epirez construction products - Epirez 633 solventless epoxy paste. Epirez advises that this product meets the requirements of AS/NZS 4020 for contact with drinking water, or Hilti (Aust) Pty. Ltd. CA 273 solventless epoxy paste.
Cement mortar lining
Crack
Steel pipe Figure B.1 - Typical cement mortar lining crack greater than 2mm.
Preparation
The CML should be dry at the time of undertaking the repair. Enlarge the crack to a width of 4 to 6mm using a 100 mm angle grinder (or equivalent) fitted with a diamond tipped cutting blade nominally 3.2mm in width. The depth of the groove should be set at 2mm less than the lining thickness. The depth should be checked with a ruler.
mm2 copper cable (ALM type ME 11-65, Wattmaster ME 60 or equivalent.) Hand crimping tool (Wattmaster MK 80, Utilux No 20 or equivalent. (See picture below.)
Note: Hydralic typecrimpers are u not suitable for crimpingthis style of lug.
4 6mm
Application
1. Mix the resin and hardener components of the epoxy paste thoroughly in the specified ratio. Mix a reasonable quantity of product to ensure that the mix ratio is achieved. Only mix an amount that can be placed within 20 minutes. Discard all product that is not used within 20 minutes. The minimum application temperature is 5C. For large repairs the easiest method of application is to fill an empty caulking gun container and apply with a caulking gun. This method pushes the epoxy into the groove to completely fill the space and exclude air. Figure B.2 - Enlarge crack to 4 6mm
Cable (19/1.35 (25 mm2) single core double insulated P.V.C. Shrink tube 100 long (Raychem WCSM 28/9 / 1200) Knife or stripping tool (For cable and 9.5 mm dia lug) Battery operated hand drill and 6.5 mm bit (17/64) Solvent (Methylated Spirits, isopropanol or acetone) and clean rags Propane/Butane heating torch with primus 2956 burner or equivalent
Fig. 1 2. Strip the Sintakote for a distance of 25 mm from the end of the lug by cutting around the full circumference of the lug and twisting the loosened Sintakote cap. (See Fig 2)
Epoxy grout
Fig. 2 Using the battery drill on low speed insert the 6.5 mm drill bit into the hole in the end of the lug to remove any residual Sintakote and clean the inside copper surface.
Figure B.3 - Completed repair
APPENDIX C
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S I N T A K O T E
S T E E L
P I P E L I N E S
S S I I N N T TA A K K O O T T E E
S T E E L
P I P E L I N E S
APPENDIX D
3. Cut the length of cable to the required length (distance between the lugs including room to bend the cable) using the cable cutters. Bare both ends of the cable for a distance of 20 mm taking care to avoid damaging the ends of the copper cable. See Fig 3 6. Clean the surface of the lug and at least 50 mm of cable next to the lug using methylated spirits and a clean rag. 7. Slide the shrink tube down to the surface of the pipe and using a low flame heat the sleeve around the location of the crimp join as shown in Fig 5. Move the flame outwards towards the cable end of the tube whilst heating the tube all around. When this is completed a small amount of adhesive/sealant will squeeze from the end of the tube.
General Data
Table D.1 SINTAKOTE Thicknesses
Pipe OD (mm) 273 >273 to 508 >508 to 762 >762 SINTAKOTE Thickness (mm) 1.6 1.8 2.0 2.3
Table D.2 Cement Mortar Lining (CML) Thickness

Pipe OD (mm) 273 >273 to 762 >762 to 1219 > 1219 to 1829 CML Thickness (mm) 93 12 4 16 4 19 4
Table D.3 SINTAKOTE Steel Pipe Bores and Weights

Cement mortar lining thickness (mm) Cement mortar lining bore (mm) Mass per metre SKCL (kg/m) Mass per metre UCCL (kg/m) SKCL PIPE Weight (tonnes) Pipe Length (m)
Fig. 3 4. Slide two lengths of shrink tube over the cable and insert the ends into the hole on the lugs of each pipe. 5. Adjust the screw on the crimp tool for 25 mm2 cable and while holding the cable firmly into the lug make a crimp close to the end of the lug. The crimp must be made from the top with the tool at 90 to the pipe surface Repeat this operation adjacent to the first crimp. (see Fig. 4)
Steel wall thickness (mm)
SINTAKOTE thickness (mm)
Steel outside diameter (mm)
12.0
114
4.8
1.6
86.4
19.9
19.4
0.1
na
na
na
114 168 190 219 240 257 273 290 305 324 324 324 324 337 337 337 337 344 344 344 344 356 356 356 356 406 406 406 406 406 419 419
4.8 5 5 5 5 5 5 5 5 4 4.5 5 6 4 4.5 5 6 4 4.5 5 6 4 4.5 5 6 4 4.5 5 6 8 4 4.5
1.6 1.6 1.6 1.6 1.6 1.6 1.6 1.8 1.8 1.8 1.8 1.8 1.8 1.8 1.8 1.8 1.8 1.8 1.8 1.8 1.8 1.8 1.8 1.8 1.8 1.8 1.8 1.8 1.8 1.8 1.8 1.8
9 9 9 9 9 9 9 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12
86.4 140 162 191 212 229 245 256 271 292 291 290 288 305 304 303 301 312 311 310 308 324 323 322 320 374 373 372 370 366 387 386
19.9 31.0 35.3 41.0 45.1 48.5 51.6 61.0 64.3 60.8 64.6 68.4 76.0 63.4 67.3 71.3 79.1 64.7 68.8 72.8 80.8 67.1 71.3 75.4 83.8 76.8 81.6 86.4 96.0 114.9 79.3 84.3
19.4 30.2 34.4 40.0 44.0 47.2 50.3 59.4 62.6 59.1 62.9 66.7 74.2 61.6 65.5 69.5 77.3 62.9 66.9 71.0 79.0 65.2 69.4 73.5 81.9 74.6 79.4 84.2 93.8 112.8 77.1 82.1
0.1 0.2 0.2 0.2 0.3 0.3 0.3 0.4 0.4 0.4 0.4 0.4 0.5 0.4 0.4 0.4 0.5 0.4 0.4 0.4 0.5 0.4 0.4 0.5 0.5 0.5 0.5 0.5 0.6 0.7 0.5 0.5
na 0.3 0.3 0.4 0.4 0.4 0.5 0.5 0.6 0.5 0.6 0.6 0.7 0.6 0.6 0.6 0.7 0.6 0.6 0.7 0.7 0.6 0.6 0.7 0.8 0.7 0.7 0.8 0.9 1.0 0.7 0.8
na na na na na na na na na na na na na na na na na na na na na na na na na 0.9 1.0 1.0 1.2 1.4 1.0 1.0
na na na na na na na na na na na na na na na na na na na na na na na na na 1.0 1.1 1.2 1.3 1.6 1.1 1.1
Fig. 5 Repeat this operation towards the pipe end until sealant squeezes out from that end. See Fig 6
Fig 4 (In the diagram above the crim p appears on thetop of the lug for illust ation pup r r oses in s practice it willbe on the side of . the lug)
C
Fig. 6 8. Repeat procedure 6 and 7 on the other lug and cable end to complete the joining operation.
APPENDIX D
13.5
9.0
6.0
| 63
S I N T A K O T E
S T E E L
P I P E L I N E S
S I N T A K O T E
S T E E L
P I P E L I N E S
Cement mortar lining thickness (mm)
Cement mortar lining bore (mm)
Mass per metre SKCL (kg/m)
Mass per metre UCCL (kg/m)
SKCL PIPE Weight (tonnes) Pipe Length (m)
12.0
12.0
13.5
9.0
6.0
419 419 419 457 457 457 457 502 502 502 502 508 508 508 508 559 559 559 559 610 610 610 610 610 648 648 648 648 648 660 660 660 660 660 660 700 700 700 700 700 700 711 711 711 711 711 711 762 762 762 762
5 6 8 4.5 5 6 8 4.5 5 6 8 4.5 5 6 8 4.5 5 6 8 4.5 5 6 8 9.5 4.5 5 6 8 9.5 4.5 5 6 8 9.5 12 4.5 5 6 8 9.5 12 4.5 5 6 8 9.5 12 4.5 5 6 8
D
1.8 1.8 1.8 1.8 1.8 1.8 1.8 1.8 1.8 1.8 1.8 1.8 1.8 1.8 1.8 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2
12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12
385 383 379 424 423 421 417 469 468 466 462 475 474 472 468 526 525 523 519 577 576 574 570 567 615 614 612 608 605 627 626 624 620 617 612 667 666 664 660 657 652 678 677 675 671 668 663 729 728 726 722
89.2 99.1 118.7 92.2 97.6 108.4 129.9 101.5 107.4 119.4 143.1 102.7 108.8 120.8 144.8 113.6 120.3 133.6 160.1 124.2 131.5 146.1 175.1 196.7 132.1 139.8 155.4 186.3 209.3 134.5 142.5 158.3 189.8 213.3 252.2 142.8 151.3 168.1 201.5 226.5 267.9 145.1 153.7 170.8 204.8 230.2 272.2 155.7 164.9 183.2 219.8
87.0 96.9 116.5 89.7 95.1 106.0 127.4 98.8 104.8 116.7 140.4 100.0 106.1 118.1 142.1 110.3 117.0 130.3 156.8 120.6 127.9 142.5 171.5 193.1 128.2 136.0 151.5 182.4 205.5 130.6 138.6 154.4 185.9 209.4 248.3 138.7 147.1 163.9 197.4 222.4 263.8 140.9 149.5 166.6 200.6 225.9 268.0 151.2 160.4 178.7 215.2
0.5 0.6 0.7 0.6 0.6 0.7 0.8 0.6 0.6 0.7 0.9 0.6 0.7 0.7 0.9 0.7 0.7 0.8 1.0 0.7 0.8 0.9 1.1 1.2 0.8 0.8 0.9 1.1 1.3 0.8 0.9 0.9 1.1 1.3 1.5 0.9 0.9 1.0 1.2 1.4 1.6 0.9 0.9 1.0 1.2 1.4 1.6 0.9 1.0 1.1 1.3
0.8 0.9 1.1 0.8 0.9 1.0 1.2 0.9 1.0 1.1 1.3 0.9 1.0 1.1 1.3 1.0 1.1 1.2 1.4 1.1 1.2 1.3 1.6 1.8 1.2 1.3 1.4 1.7 1.9 1.2 1.3 1.4 1.7 1.9 2.3 1.3 1.4 1.5 1.8 2.0 2.4 1.3 1.4 1.5 1.8 2.1 2.4 1.4 1.5 1.6 2.0
1.1 1.2 1.4 1.1 1.2 1.3 1.6 1.2 1.3 1.4 1.7 1.2 1.3 1.4 1.7 1.4 1.4 1.6 1.9 1.5 1.6 1.8 2.1 2.4 1.6 1.7 1.9 2.2 2.5 1.6 1.7 1.9 2.3 2.6 3.0 1.7 1.8 2.0 2.4 2.7 3.2 1.7 1.8 2.0 2.5 2.8 3.3 1.9 2.0 2.2 2.6
1.2 1.3 1.6 1.2 1.3 1.5 1.8 1.4 1.5 1.6 1.9 1.4 1.5 1.6 2.0 1.5 1.6 1.8 2.2 1.7 1.8 2.0 2.4 2.7 1.8 1.9 2.1 2.5 2.8 1.8 1.9 2.1 2.6 2.9 3.4 1.9 2.0 2.3 2.7 3.1 3.6 2.0 2.1 2.3 2.8 3.1 3.7 2.1 2.2 2.5 3.0
762 762 800 800 800 800 800 800 813 813 813 813 813 813 914 914 914 914 914 960 960 960 960 960 965 965 965 965 965 1,016 1,016 1,016 1,016 1,067 1,067 1,067 1,067 1,086 1,086 1,086 1,086 1,124 1,124 1,124 1,124 1,200 1,200 1,200 1,200
9.5 12 4.5 5 6 8 9.5 12 4.5 5 6 8 9.5 12 6 8 10 12 16 6 8 10 12 16 6 8 10 12 16 8 10 12 16 8 10 12 16 8 10 12 16 8 10 12 16 8 10 12 16
2 2 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3
12 12 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16
719 714 759 758 756 752 749 744 772 771 769 765 762 757 870 866 862 858 850 916 912 908 904 896 921 917 913 909 901 968 964 960 952 1019 1015 1011 1003 1038 1034 1030 1022 1076 1072 1068 1060 1152 1148 1144 1136
247.0 292.2 187.3 197.0 216.2 254.5 283.0 330.4 190.4 200.2 219.8 258.7 287.8 335.9 247.6 291.5 335.2 378.7 465.2 260.3 306.4 352.4 398.2 489.2 261.7 308.1 354.3 400.3 491.8 324.6 373.4 421.9 518.4 341.2 392.5 443.5 545.0 347.4 399.6 451.6 555.0 359.7 413.8 467.7 574.8 384.4 442.2 499.9 614.5
242.5 287.7 181.9 191.5 210.7 249.0 277.6 325.0 184.9 194.7 214.2 253.2 282.2 330.4 241.4 285.3 329.0 372.5 458.9 253.7 299.9 345.9 391.7 482.6 255.1 301.5 347.7 393.8 485.2 317.7 366.5 415.0 511.5 333.9 385.2 436.3 537.8 340.0 392.2 444.2 547.6 352.1 406.1 460.0 567.2 376.3 434.1 491.7 606.3
1.5 1.8 1.1 1.2 1.3 1.5 1.7 2.0 1.1 1.2 1.3 1.6 1.7 2.0 1.5 1.7 2.0 2.3 2.8 1.6 1.8 2.1 2.4 2.9 1.6 1.8 2.1 2.4 3.0 1.9 2.2 2.5 3.1 2.0 2.4 2.7 3.3 2.1 2.4 2.7 3.3 2.2 2.5 2.8 3.4 2.3 2.7 3.0 3.7
2.2 2.6 1.7 1.8 1.9 2.3 2.5 3.0 1.7 1.8 2.0 2.3 2.6 3.0 2.2 2.6 3.0 3.4 4.2 2.3 2.8 3.2 3.6 4.4 2.4 2.8 3.2 3.6 4.4 2.9 3.4 3.8 4.7 3.1 3.5 4.0 4.9 3.1 3.6 4.1 5.0 3.2 3.7 4.2 5.2 3.5 4.0 4.5 5.5
3.0 3.5 2.2 2.4 2.6 3.1 3.4 4.0 2.3 2.4 2.6 3.1 3.5 4.0 3.0 3.5 4.0 4.5 5.6 3.1 3.7 4.2 4.8 5.9 3.1 3.7 4.3 4.8 5.9 3.9 4.5 5.1 6.2 4.1 4.7 5.3 6.5 4.2 4.8 5.4 6.7 4.3 5.0 5.6 6.9 4.6 5.3 6.0 7.4
3.3 3.9 2.5 2.7 2.9 3.4 3.8 4.5 2.6 2.7 3.0 3.5 3.9 4.5 3.3 3.9 4.5 5.1 6.3 3.5 4.1 4.8 5.4 6.6 3.5 4.2 4.8 5.4 6.6 4.4 5.0 5.7 7.0 4.6 5.3 6.0 7.4 4.7 5.4 6.1 7.5 4.9 5.6 6.3 7.8 5.2 6.0 6.7 8.3
APPENDIX D
| 65
13.5
9.0
6.0
S I N T A K O T E
S T E E L
P I P E L I N E S
S I N T A K O T E
S T E E L
P I P E L I N E S
Wall Thickness (mm)
Wall Thickness (mm)
Rated Pressure (MPa) 3.9 4.6 6.2 3.2 3.5 4.2 5.7 5.6 3.0 3.3 4.0 5.3 5.3 2.9 3.3 3.9 5.2 5.2 6.5 2.8 3.1 3.7 4.9 4.9 6.2 2.7 3.0 3.6 4.9 4.8 6.1 2.6 2.8 3.4 4.5 4.5 5.7 2.4 2.7 3.2 4.3 4.3 5.4 2.4 2.7 3.2 4.3 4.2 5.3
1,219 1,219 1,219 1,219 1,283 1,283 1,283 1,283 1,290 1,290 1,290 1,290 1,404 1,404 1,404 1,404 1,422 1,422 1,422 1,422 1,440 1,440 1,440 1,440 1,575 1,575 1,575 1,575 1,750 1,750 1,750 2,159 2,159 2,159
8 10 12 16 8 10 12 16 8 10 12 16 8 10 12 16 8 10 12 16 8 10 12 16 8 10 12 16 10 12 16 10 12 16
2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3
16 16 16 16 19 19 19 19 19 19 19 19 19 19 19 19 19 19 19 19 19 19 19 19 19 19 19 19 19 19 19 na na na
1171 1167 1163 1155 1229 1225 1221 1213 1236 1232 1228 1220 1350 1346 1342 1334 1368 1364 1360 1352 1386 1382 1378 1370 1521 1517 1513 1505 1692 1688 1680 na na na
390.6 449.3 507.9 624.4 439.3 501.1 562.7 685.4 441.7 503.9 565.9 689.2 481.3 549.1 616.7 751.3 487.6 556.3 624.7 761.1 493.9 563.4 632.8 770.9 540.8 617.0 693.0 844.5 686.4 771.1 939.8 na na na
382.3 441.0 499.6 616.1 430.6 492.4 554.0 676.6 432.9 495.1 557.1 680.4 471.8 539.6 607.2 741.7 477.9 546.6 615.1 751.4 484.1 553.6 623.0 761.1 530.1 606.3 682.3 833.7 674.5 759.2 927.9 na na na
2.3 2.7 3.0 3.7 2.6 3.0 3.4 4.1 2.7 3.0 3.4 4.1 2.9 3.3 3.7 4.5 2.9 3.3 3.7 4.6 3.0 3.4 3.8 4.6 3.2 3.7 4.2 5.1 4.1 4.6 5.6 na na na
3.5 4.0 4.6 5.6 4.0 4.5 5.1 6.2 4.0 4.5 5.1 6.2 4.3 4.9 5.6 6.8 4.4 5.0 5.6 6.8 4.4 5.1 5.7 6.9 4.9 5.6 6.2 7.6 6.2 6.9 8.5 na na na
4.7 5.4 6.1 7.5 5.3 6.0 6.8 8.2 5.3 6.0 6.8 8.3 5.8 6.6 7.4 9.0 5.9 6.7 7.5 9.1 5.9 6.8 7.6 9.3 6.5 7.4 8.3 10.1 8.2 9.3 11.3 na na na
5.3 6.1 6.9 8.4 5.9 6.8 7.6 9.3 6.0 6.8 7.6 9.3 6.5 7.4 8.3 10.1 6.6 7.5 8.4 10.3 6.7 7.6 8.5 10.4 7.3 8.3 9.4 11.4 9.3 10.4 12.7 na na na
114 168 190 219 240 257 273 290 305 324 324 324 324 337 337 337 337 344 344 344 344 356 356 356 356 406 406 406 406 406 419 419 419 419 419 457 457 457 457 502 502 502 502 508 508 508 508 559
4.8 5 5 5 5 5 5 5 5 4 4.5 5 6 4 4.5 5 6 4 4.5 5 6 4 4.5 5 6 4 4.5 5 6 8 4 4.5 5 6 8 4.5 5 6 8 4.5 5 6 8 4.5 5 6 8 4.5
8.5 8.5 8.5 8.5 8.5 8.5 8.5 8.5 8.5 6.7 7.5 8.3 8.5 6.4 7.2 8.0 8.5 6.3 7.1 7.8 8.5 6.1 6.8 7.6 8.5 5.3 6.0 6.7 8.0 8.5 5.2 5.8 6.4 7.7 8.5 5.3 5.9 7.1 8.5 4.8 5.4 6.5 8.5 4.8 5.3 6.4 8.5 4.3
866 866 866 866 866 866 866 866 866 679 764 849 866 653 735 817 866 640 720 800 866 618 696 773 866 542 610 678 813 866 525 591 657 788 866 542 602 723 866 493 548 658 866 488 542 650 866 443
6.8 6.8 6.8 6.8 6.8 6.8 6.8 6.8 6.8 5.3 6.0 6.7 6.8 5.1 5.8 6.4 6.8 5.0 5.7 6.3 6.8 4.9 5.5 6.1 6.8 4.3 4.8 5.3 6.4 6.8 4.1 4.6 5.2 6.2 6.8 4.3 4.7 5.7 6.8 3.9 4.3 5.2 6.8 3.8 4.3 5.1 6.8 3.5
693 693 693 693 693 693 693 693 693 544 612 679 693 523 588 653 693 512 576 640 693 495 557 618 693 434 488 542 651 693 420 473 525 630 693 434 482 578 693 395 439 526 693 390 433 520 693 354
559 559 559 610 610 610 610 610 648 648 648 648 648 660 660 660 660 660 660 700 700 700 700 700 700 711 711 711 711 711 711 762 762 762 762 762 762 800 800 800 800 800 800 813 813 813 813 813 813
5 6 8 4.5 5 6 8 9.5 4.5 5 6 8 9.5 4.5 5 6 8 9.5 12 4.5 5 6 8 9.5 12 4.5 5 6 8 9.5 12 4.5 5 6 8 9.5 12 4.5 5 6 8 9.5 12 4.5 5 6 8 9.5 12
4.8 5.8 7.7 4.0 4.4 5.3 7.1 7.0 3.8 4.2 5.0 6.7 6.6 3.7 4.1 4.9 6.5 6.5 8.2 3.5 3.9 4.6 6.2 6.1 7.7 3.4 3.8 4.6 6.1 6.0 7.6 3.2 3.5 4.3 5.7 5.6 7.1 3.0 3.4 4.1 5.4 5.3 6.8 3.0 3.3 4.0 5.3 5.3 6.6
492 591 788 406 451 541 722 714 382 425 510 679 672 375 417 500 667 660 834 354 393 472 629 622 786 348 387 464 619 613 774 325 361 433 578 572 722 310 344 413 550 545 688 305 338 406 542 536 677
Notes: Pipe masses may vary +/- 10 % due to material tolerances Calculations based on: Steel shell 0.02466(D-t)t Cement lining 0.00755T(D-2t-T) SINTAKOTE 0.00296Dts where D = outside diameter of pipe (mm) T = cement lining thickness (mm) Total mass may carry minor round-off error t = steel wall thickness (mm) ts= SINTAKOTE thickness (mm)
APPENDIX D
| 67
Rated Pressure (m) 394 473 630 325 361 433 577 571 306 340 408 544 538 300 334 400 534 528 667 283 314 377 503 498 629 279 310 372 495 490 619 260 289 347 462 457 578 248 275 330 440 436 550 244 271 325 433 429 542
Rated Pressure (MPa)
Rated Pressure (m)
Outside Diameter (mm)
Table D.4- Manufacturing Test Pressure and Rated Pressure for MSCL Pipes
Test Pressure (MPa) Test Pressure (m) Test Pressure (m) Test Pressure (MPa)
12.0
13.5
9.0
6.0
S I N T A K O T E
S T E E L
P I P E L I N E S
S I N T A K O T E
S T E E L
P I P E L I N E S
Wall Thickness (mm)
Rated Pressure (MPa)
Rated Pressure (m)
Wall Thickness (mm)
Rated Pressure (MPa) 2.5 2.6 3.1 4.1 2.4 2.5 3.0 4.1 2.4 2.5 3.0 4.0 2.2 2.3 2.7 3.7 2.1 2.5 3.3 1.7 2.0 2.7
Test Pressure (MPa)
Test Pressure (m)
914 914 914 914 914 960 960 960 960 960 965 965 965 965 965 1,016 1,016 1,016 1,016 1,067 1,067 1,067 1,067 1,086 1,086 1,086 1,086 1,124 1,124 1,124 1,124 1,200 1,200 1,200 1,200 1,219 1,219 1,219 1,219 1,283 1,283 1,283 1,283 1,290 1,290 1,290 1,290
6 8 10 12 16 6 8 10 12 16 6 8 10 12 16 8 10 12 16 8 10 12 16 8 10 12 16 8 10 12 16 8 10 12 16 8 10 12 16 8 10 12 16 8 10 12 16
3.5 4.7 4.9 5.9 7.9 3.4 4.5 4.7 5.6 7.5 3.4 4.5 4.7 5.6 7.5 4.3 4.4 5.3 7.1 4.0 4.2 5.1 6.8 4.0 4.1 5.0 6.6 3.8 4.0 4.8 6.4 3.6 3.8 4.5 6.0 3.5 3.7 4.4 5.9 3.4 3.5 4.2 5.6 3.3 3.5 4.2 5.6
361 482 502 602 803 344 459 478 573 764 342 456 475 570 760 433 451 542 722 413 430 516 688 405 422 507 676 392 408 490 653 367 382 459 611 361 376 451 602 343 357 429 572 341 356 427 569
2.8 3.8 3.9 4.7 6.3 2.7 3.6 3.8 4.5 6.0 2.7 3.6 3.7 4.5 6.0 3.4 3.5 4.2 5.7 3.2 3.4 4.1 5.4 3.2 3.3 4.0 5.3 3.1 3.2 3.8 5.1 2.9 3.0 3.6 4.8 2.8 3.0 3.5 4.7 2.7 2.8 3.4 4.5 2.7 2.8 3.4 4.5
289 385 401 482 642 275 367 382 459 611 274 365 380 456 608 347 361 433 578 330 344 413 550 324 338 405 541 313 326 392 522 294 306 367 489 289 301 361 482 275 286 343 458 273 284 341 455
1,404 1,404 1,404 1,404 1,422 1,422 1,422 1,422 1,440 1,440 1,440 1,440 1,575 1,575 1,575 1,575 1,750 1,750 1,750 2,159 2,159 2,159
8 10 12 16 8 10 12 16 8 10 12 16 8 10 12 16 10 12 16 10 12 16
3.1 3.2 3.9 5.1 3.0 3.2 3.8 5.1 3.0 3.1 3.8 5.0 2.7 2.9 3.4 4.6 2.6 3.1 4.1 2.1 2.5 3.3
314 327 392 523 310 323 387 516 306 319 382 510 280 291 349 466 262 314 419 212 255 340
Maximum test pressure =90% of yield stress of steel, but not greater than 8.5 MPa. Rated pressure =72% of yield stress of steel, but not greater than 6.8 MPa. Yield stress of steel = 300MPa for t<=8.0mm, 250MPa for t>8.0mm. where t is steel wall thickness (mm). Working pressure is determined by the designer after consideration of the Rated Pressure of the pipe and fittings and taking into account the various factors such as external loads and transient hydrostatic conditions.
Rated Pressure (m) 251 261 314 418 248 258 310 413 245 255 306 408 224 233 280 373 210 252 335 170 204 272
Test Pressure (m)
Test Pressure (MPa)

MSCL Handling Instal Manual 2007

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S I N T A K O T E

Handling & Installation Reference Manual

List of Figures & Tables

List of Figures & Tables

(continued) Figure 10.1 - Common fittings - welded pipelines ..............................................................43

SINTAKOTE Training Program

Protect the pipe and coating

Figure 1.1 Securing pipes for transport 12 | C H A P T E R 1

3. Unloading and Handling

Vacuum Lifting Devices

4. Stacking and Storage

Stacking heights for long term storage

Figure 4.1 - Pipe support

Table 4.1- Minimum pipe support area

Before pipe delivery

Method of stringing pipes

Storage of Cement Mortar Lined Pipes

What equipment to use

How wide should the trench be?

How deep should the trench be?

Pipes strung with sockets facing direction of laying

Figure 6.1- Trench excavation machinery

Bedding in wet or unstable ground

How to put bedding into a trench

Shoring the trench

Allowance for sling withdrawal

What to use for bedding

8. Laying and Jointing

After assembly Figure 8.2- Pulling SINTAJOINT pipes home to joint

Inspection of Pipe Before Laying

Spherical slip-on joint

Ball and socket joint

Plain butt joint

Butt joint with collar

SINTAKOTE at pipe ends

Common flange joint

Figure 8.1- Jointing systems

leaving the manufacturer. Damaged rings must not be used.

Laying and Jointing of Pipe

Figure 8.3- Fitting rubber rings into sockets

Max permissible misalignment (degrees) 6m

Joint assembly with puller

Important note for concave changes in direction

800 700 600

Deflection Angle (degrees)

Inspection of assembled joint

External check (see Figure 8.7)

Summary of Important Points for Laying and Jointing: SINTAJOINT Pipes

Maximum Operating Pressure MPa 1.6 3.5

Solid EPDM Rubber 3mm thick Composit Fibre 1.5mm thick

Flange bolts and assembly torque

Figure 8.12 Star pattern tightening sequence

Jointing instructions for flanged joints

Tension Stainless Steel

Zone B - Backfill for haunch support, side support and overlay

Zone C - Overburden trench fill

Zones of backfill and compaction

Mitred Bend 0 to 22.5

Mitred Bend 22.5 to 45

Ring deflection limits

1 metre short Figure 9.2- Ring deflection limits

11. Anchorage of Pipelines

Anchor blocks for horizontal thrust-buried mains